Weber Geset 121 User manual

Original User’s Manual
Installation, Setup, Operation and Maintenance
Geset 121
Article number of documentation 32708732
Copyright ©, Weber Marking Systems GmbH
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: [email protected]
http://www.webermarking.de
Version: 02.08.12 /GRN
32708732

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Content 32708732 Geset 121
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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............................................................................................................14
Behavior in an emergency.................................................................................................14
Basic safety guidelines......................................................................................................14
Meaning of the hazard levels...................................................................................................... 14
Intended use......................................................................................................................15
Reasonably foreseeable misuse........................................................................................16
Modifications and alterations to the labeling station..........................................................16
Hazards to the labeling system..........................................................................................17
Safety instructions....................................................................................................................... 17
Remaining risks.................................................................................................................20
Warnings on the labeling system.......................................................................................21
Approved persons..............................................................................................................22
Personal Protective Gear...................................................................................................23
Protection Devices.............................................................................................................24
*² System cover........................................................................................................................... 24
*² Main switch.............................................................................................................................. 24
*² Emergency-Stop Push Button.................................................................................................24
*²Safety switch............................................................................................................................. 25
Workplaces for the operating personnel............................................................................25
Waste disposal ..................................................................................................................25
3.Specifications ..................................................................................................................26
Information on operation............................................................................................................. 26
Noise level................................................................................................................................... 26
4.Transport..........................................................................................................................27
Delivery..............................................................................................................................27
Scope of the delivery................................................................................................................... 27
Transportation and unpacking...........................................................................................27

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Safety instructions....................................................................................................................... 27
Storage conditions.............................................................................................................30
5.Description of the labeling station.................................................................................31
Function and Field of Application of the Labeling System.................................................31
Complete overview............................................................................................................31
6.Installation and initial startup.........................................................................................32
Safety instructions....................................................................................................................... 32
Installation..........................................................................................................................33
Requirements at the installation site........................................................................................... 33
Placing the labeling system......................................................................................................... 33
Setting up the labeling system...........................................................................................34
Connecting the labeling station..........................................................................................34
Connection to supply voltage.............................................................................................35
Safety instructions....................................................................................................................... 35
*² Connecting to compressed air................................................................................................. 36
Safety instructions....................................................................................................................... 36
7.Adjustment and initial operation of labeling system ...................................................38
Safety instructions....................................................................................................................... 38
Adjustment and initial operation.........................................................................................39
Adjust side guidance................................................................................................................... 40
Change peeler blade................................................................................................................... 41
Pitch peeler blade (Gimbal adjustment)...................................................................................... 42
Insert label roll in labeler............................................................................................................. 44
Insert label liner in labeler........................................................................................................... 44
*²Wrap belt (Wrap around labeling)............................................................................................. 45
Move label position in transport direction forward or backward.................................................. 47
Correct adjustments after labeling result...........................................................................48
8.Operation..........................................................................................................................50
Safety instructions....................................................................................................................... 50
Operating- and display elements.......................................................................................51
Turn on and off machine............................................................................................................. 51
Operator panel ............................................................................................................................ 51
Turn on labeling operation.................................................................................................52
Turning off the system.......................................................................................................53
Putting the system out of service.......................................................................................54
Acknowledge errors...........................................................................................................55
9.Maintenance.....................................................................................................................56
Sicherheitshinweise..................................................................................................................... 56
Inspection- and maintenance list................................................................................................. 57

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Daily servicing (after approximately 8 hours of operation).......................................................... 57
Weekly servicing (after approximately 40 hours of operation).................................................... 58
Quarterly servicing (after approximately 500 hours of operation)............................................... 58
Annual servicing (after approximately 2000 hours of operation) ................................................ 59
Inspection ..........................................................................................................................60
Maintenance light sensor and light barrier.........................................................................61
Safety instructions....................................................................................................................... 61
Maintenance instruction conveying systems .....................................................................62
Safety instructions....................................................................................................................... 62
General description of the conveying system ............................................................................. 62
Check transport belts .................................................................................................................. 63
Retensioning the strap and the drive chain................................................................................. 64
Belt run correction....................................................................................................................... 65
Exchange of rollers...................................................................................................................... 66
Clean drive belts and transport belts........................................................................................... 67
Safety instructions....................................................................................................................... 67
Spare parts........................................................................................................................67
Safety instructions....................................................................................................................... 67
Wiring diagram...................................................................................................................67
10.Troubleshooting..........................................................................................................68
Safety instructions....................................................................................................................... 68
Remedy of defects.............................................................................................................69
Failures at the Labeling system .................................................................................................. 69
Failures at the Labeling System.................................................................................................. 69
11.Index.............................................................................................................................70
12.EC Declaration of conformity.....................................................................................71

Chapter 1 General information 32708732 Geset 121
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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 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 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 Weber
Marking Systems 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.

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Purpose and overview of the operating instructions
These operating instructions will help you get to know the system and use it properly.
They contain important instructions for the user on how to use the system safely and
correctly. Please comply with this information to avoid hazards, minimize repair costs and
outages, and to 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 and switches that need to be pressed are placed in brackets.
Ex.: Press the [Start] button to accept the changes...
Procedures that need to be performed in a fixed sequence have to be numbered.
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.
Some illustrations only show one version (for example, only the right-handed or left-
handed version or only [System1]…), especially when the information is transferable
to other versions.
Step Procedure
1 Pull the power plug...

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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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Explanation of the terms used
Term Explanation
3-roll system Is used for labeling around of round products.
Adhesive strings Glue that has leaked out at the edge of the label can hold the
label to the backing paper. The printed label remains stuck to
the backing paper and cannot be moved to the tamp pad.
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
applicator and labeling the product).
Application mode See explanations: Tamp on, tamp blow, blow on and wipe on.
Applicator This identifies the label dispenser and mimic that moves the
tamp.
Automatic mode See labeling operation
Blow-on Contact-less application mode in which the tamp receives the
printed label by a vacuum and blows it on to the product
without the tamp moving.
Chain orientation The chain orientation aligns rectangular and oval products
parallel and centered at the transport belt.
Change separation device To label the fed products, they have to be fed separately to
the labeling system. The separation device separates the
products.
Contrast Difference in brightness of light and dark sections of a picture
/ print.
Conveying system The unit consisting of the conveyor belt and its control
Conveyor Belt for conveying the product
CS Abbreviation for conveying system (see above)
Cycle Steps of labeling from the detection of product, to the labeling
of the product, to the return to the initial position of the tamp.
Cylinder Home-Position
Sensor Sensor to detect home position if the cylinder is retracted.
Dancer arm The arm that holds the label liner taught by spring tension.

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Term Explanation
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.
DIP switches DIP stands for "dual in-line package." Dip switches are
miniature switches that have 4 to 8 switches. The status
(open/closed) can be changed by turning the switches with a
pointed object (pencil, etc.) The configuration of the labeling
system is determined by the switch position.
Display Display field that shows the status to the user.
Display-Controller Controller with integrated display panel for text information (s.
display) and key panel for operation and programming.
Edge detection The edge (front or back) of a product or label is used by a
sensor to detect the product or label gap.
Feed (label feed) Press the [Feed] button to advance a label.
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.
Home position Basic position of the tamp at the peeler bar
Home position sensor Sensor for detecting the end position when the tamp is in
home position
Hotline A service for offering customers quick telephone diagnosis
HPU Height positioning unit - a device powered by motor or
pneumatic drive for elevating vertically a labeling system. The
labeling system can be moved into various vertical positions.
Infeed The products are fed manually or by a (customized)
conveying system at infeed of the labeling system.
Label Applicator See labeling system
Label Feed The advancement of a label. While printing or when the [Feed]
button is pressed, the drive motor for the print module is
activated, and the label liner is transported (the dancer arm
releases the unwinder brake). The advanced label is printed in
the print module, and the peeler bar is separated from the
backing paper.
Label gap sensor See label sensor
Label Gap Distance between two labels on the backing. The dispenser
detects the gap by a (label) sensor
Label Liner Silicon-coated backing to which individual labels are adhered.
Label Out An optical sensor (reflective light sensor) for detecting the end
of the labels

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Term Explanation
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 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.
Leading Edge The leading edge of a product/label is used to trigger a
process (s. a. edge detection).
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 warning
Mandrel A powered shaft with an attachment for mounting the label
liner. The mandrel winds the backing.
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.
Peeler bar Metal bar that is used to peel off the label. The peeler bar is
below the printhead when the print module is used for
labeling.
Photocell Product sensor. The sensor identifies the product to be
labeled and generates the trigger signal. See trigger signal
Piston The piston affects on the mandrel for the linear movement of
the cylinder and transfers compressed air to movement.
PLC Programmable logic controller.
Pneumatic systems Compressed air is used as an energy source for generating
movement and flow.
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)
Pressure Gauge See service unit
Pressure rollers Pushes the label onto the product adhesively.
Product Delay An adjustable delay between the time at which the product is
detected to the start of the dispensing cycle.

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Term Explanation
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).
Reset Command for the resetting software systems to their defaults
which is usually activated by a combination of keys.
Rewinder Holder (generally for three-inch cardboard core) for winding
the label backing strip. The rewinder winds the backing paper
that is returned from the printing module. It is controlled by the
dancer arm (see dancer arm). Rewinders have a motorized
drive.
Re- and Unwinder See rewinder and unwinder.
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 .
Round plate The round plate is turned by a motor and it is used to feed the
products tot he inlet or to take the product from runout.
Runout The runout forwards the products to the customer’s conveying
system. Here the products are removed.
Sensor for variable stroke A proximity sensor that is attached to the tamp and identifies
the product. The label is blown on and applied during product
detection.
Service unit (FR group) This unit consists of:
A gauge for displaying the compression of the
compressed air (in bar)
Quick action stop valve
Water trap for manually draining any condensate
Start sensor 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.
Stroke Way the tamp moves during extension in direction of product.
Tamp Unit that grabs the label by means of a vacuum, conveys it to
the product and applies it.
Tamp pad
(suction/blowing tamp) Perforated plate of the tamp to which the peeled off label is
transferred.
Tamp travel time Duration of tamp movement (extension and backfeed) during
a labeling cycle.
Tamp-blow Contact-less application mode in which the tamp takes a
printed label by means of a vacuum, conveys it to the product
and blows it on to the product.

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Term Explanation
Tamp-on Application mode in which the tamp takes a printed label by
means of a vacuum, conveys it to the product and presses it
on to the product.
Product Delay An adjustable delay between the time at which the product is
detected to the start of the dispensing cycle.
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).
Top conveyor The top conveyor is placed parallel above the transport belt
and can be adjusted in height. It is used to fasten the products
during labeling.
Touchscreen Touch-controlled screen or monitor
Trailing Edge The trailing edge of a product is used to trigger a process
(s. a. edge detection).
Trailing edge See Leading Edge.
Transport belt The transport belt transports the products that should be
labeled.
Trigger-signal The signal from the sensor or PLC which is used to activate
application.
Unwinder The unwinder receives the roll of labels (generally with a 3
inch cardboard core). The unwinder allows the label roll to
unwind smoothly without skipping, and a roll brake governs
the feed (see also the dancer arm). Unwinders can also have
a motor drive
VAC Alternating voltage
Vacuum belt The vacuum belt moves round products in rotation and
enables thus an all around labeling.
Vacuum generator
(Venturi) An unit that uses compressed air to generate a vacuum.
VDC Direct current voltage
Water trap See service unit
Web Label liner consisting of a silicon-coated backing and the
individual labels adhering to it.
Wipe-On Labeling procedure at which the label is peeled off by a peeler
blade and directly forwarded to the product. Label feed and
product speed have to be identical.
Zero-/Home-Position-
Sensor : This sensor is activated if the tamp arrives the zero position.

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2. Safety regulations
Behavior in an emergency
The operating personnel must know the location of and how to use safety equipment, alarms,
first aid and rescue equipment.
What to do in an emergency?
If individuals, body parts or objects become caught in the moving parts of the
labeling system, immediately disconnect the compressed air and power supply to
the labeling system.
Immediately perform all necessary first-aid on injured persons. Observe the
applicable safety regulations to prevent additional personal injury.
Obtain medical help for injured persons.
Eliminate all the causes of the accident.
Basic safety guidelines
Safety guidelines offer information the form 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 will cause serious
injury or death. To prevent personal injury, all safety instructions
must be observed.
The symbol indicates a hazardous situation that can lead to
serious injury or death. To prevent personal injury, all safety
instructions must be observed.
The symbol indicates a hazardous situation that can lead to
moderate or light injury. To prevent personal injury, all safety
instructions must be observed.
The symbol indicates a hazardous situation that can lead to
property damage. To prevent property damage, all warnings must
be observed.

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Intended use
The operational safety of the system Geset 121 is guaranteed only if it is used as
intended.
Intended use consists of the following …
The labeling system may only be used for automatically labeling moving and
stationary products.
The labeling system may only be worked on manually after it stops.
The labeling system is used for the specific products agreed with the customer with
the specific, agreed labels. In every way, the products and labels must satisfy the
documented* specifications agreed between the machine manufacturer and
customer.
* "Documented specifications" are laid down in the MES (Machine and Equipment Standard, Continental).
the labeling system is operating in explosion-proof environments (not intended for
explosion-risk areas) !
the labeling system does not come in direct contact with food products.
the labeling system is not operating outdoors.
the labeling system 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 particles.
the labeling system is used exclusively for industrial purposes.
all working conditions and instructions, prescribed in this manual, will be observed.
failures at the labeling system affecting the safety have to be reported and
immediately resolved by trained and briefed personnel.
maintenance is kept and performed correctly.
the labeling system is used exclusively under faultless conditions.
safety equipments are not by-passed or abrogated.
arbitrary changes at the machine are omitted.
the labeling system is used or operated by adequate personnel, refer to “Approved
persons” (s. page 22). These persons must have read and have to be familiar with
the content of the manual.
Handling the labeling system without considering one of these points is not for the
intended purpose and can cause serious damages to persons or properties.

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Reasonably foreseeable misuse
Usage different than or going beyond that specified under "Intended use" is considered
unauthorized.
The operator bears sole responsibility for
Damage arising from improper use.
Furthermore, the manufacturer assumes no liability for such use.
Improper use can cause exposure to risk.
Improper use includes e.g. the following:
Operating in an 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
devices not described in these operating instructions.
The electromagnetic behavior of the machine can be impaired by additions or changes.
Do not change or modify the machine without first consulting the manufacturer and
obtaining the written approval.

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Hazards to the labeling system
Fig. 2-1: Hazards to the labeling system
Safety instructions
Hazard from direct or indirect contact with voltage-
conducting parts.
DANGER TO LIFE!
When individuals touch parts that conduct electricity arising from
malfunctions.


Only electricians may work on the switch cabinet and electri-
cal equipment.
 Regularly check the electrical equipment of the labeling
system. Immediately take care of loose connections and
damaged cables.
 Always keep the switch cabinet locked.
 Before working on electrical equipment, switch the miniature
circuit breaker to "0" position and secure it against being ac-
cidentally turned on. If possible, disconnect the power.

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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.
Danger of being pulled in by rotating elements
DANGER OF BEING PULLED IN!
Rotating elements on the labeling system.
Backing rewinder (driven by a stepper motor) and the label feed
on the labeling system or in the print module (driven by stepper
motor).
- Do not stick anything in, on or between the moving parts.
Hazards from actively controlled movements.
RISK OF INJURY FROM CRUSHING!
The movements of the labeling system are motor-driven by an
automatic controller.
- Maintain a distance from moving parts.
Danger to health from the improper use of lubricants and
cleaners.
HEALTH HAZARD!
The instructions in the manufacturer's current safety data sheets
for the specific lubricants and cleaners that are used must be
observed along with the applicable safety and disposal
regulations.
Tripping hazard from connecting lines.
RISK OF INJURY!
Connecting lines for power, compressed air and computer and
signal lines can pose a tripping hazard, causing serious injury.
 Release the tension of connecting lines to the system and run
them so that they do not pose a hazard.

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Danger of injury from corners and edges.
RISK OF INJURY!
Scrapes and cuts can result from sharp edges and pointed
corners. Always keep the work area clean. The label web has
sharp edges.
Observe caution when working close to sharp edges and pointed
corners. Remove unnecessary objects.
 In case of doubt, wear protective gloves.
 Be careful when inserting and changing label web.
*² Danger due to hot surface.
RISK OF INJURY!
At *²print head,*²forming tamp and *servo motor high surface
temperatures may exist.
- Maintain a distance from the hot surfaces.
- If work has to be performed at these assembly parts, wear
protective gloves or turn off the system and let the
components cool down.
*² Danger due to compressed air.
HEALTH HAZARD!
Whipping compressed air hoses, thrown parts or uncontrolled
moving parts can cause injury.
The compressed air connection may only be connected to a
compressed air supply that is secured against compressed air
overstepping. When connecting the compressed air, the
pneumatically powered components move to its home position.
 Maintain a distance from pneumatically moved components.
 If work has to be performed at pneumatic components, the
system has to be bled and secured against resetting.
 Before connecting the compressed air, check to ensure that all
pneumatic connections are correctly seated and secure if
necessary.
*² only if system has the appropriate features.

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*² Risk of injury due to light beam.
RISK OF INJURY!
*²Sensors or *²camera illumination may have a strong light
intensity.
Do not look into the source of light.
*² 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 construction but can be minimized with the corresponding safety mech-
anisms and equipment. A certain residual risk always exists when operating machinery.
Knowledge about residual risks of the system helps you to increase your safety
awareness and avoid accidents. To prevent hazards, observe the special safety
instructions and each chapter. Connection to the customer’s conveying system may evoke
dangerous areas at the changeovers. Suitable safety measures have to be taken in this
case.