Weber Geset 125 Product information sheet
Original User’s Manual
Installation, Setup, Operation and Maintenance
Geset 125
Article number of documentation 40001136
Copyright ©, Weber Marking Systems GmbH
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
http://www.webermarking.de
Version: 30.07.14 /ZIM
40001136
Blank Page
Content 40001136 Geset 125
Version: 30.07.14 Page 3 of 57 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.......................................................................................17
Remaining risks .................................................................................................................17
Obligations of the operator.................................................................................................18
Authorized persons............................................................................................................18
Personal protective gear....................................................................................................19
Protection devices..............................................................................................................20
*² Labeling station‘s cover............................................................................................................20
*² Main switch...............................................................................................................................20
*² Emergency-Stop Push Button..................................................................................................20
Working places for the operator personnel........................................................................21
Waste disposal...................................................................................................................21
3.Specifications......................................................................................................22
Performance data.........................................................................................................................22
Information on operation..............................................................................................................22
Noise level....................................................................................................................................22
4.Description of the labeling system....................................................................23
Complete overview.............................................................................................................24
5.Transport .............................................................................................................25
Delivery..............................................................................................................................25
Scope of the delivery....................................................................................................................25
Transportation and unpackaging........................................................................................25
Safety instructions........................................................................................................................25
Storage conditions .............................................................................................................28
6.Installation and initial startup ............................................................................29
Safety instructions........................................................................................................................29
Installation..........................................................................................................................29
Content 40001136 Geset 125
Version: 30.07.14 Page 4 of 57 GB
Requirements at the installation site............................................................................................29
Placing the labeling system .........................................................................................................30
Setting up the labeling system...........................................................................................30
Connecting the labeling station..........................................................................................30
Connection to supply voltage.............................................................................................31
7.Adjustment and initial operation .......................................................................32
Safety instructions........................................................................................................................32
Positioning device and scales............................................................................................33
Clamp lever for adjustment or interlock .......................................................................................34
Spindle adjustments and digital counter......................................................................................34
Record of adjustment values .......................................................................................................34
Adjustment and initial operation.........................................................................................35
Adjust roll conveyor......................................................................................................................36
Adjust side guidance....................................................................................................................37
Adjust wrapping unit.....................................................................................................................38
Insert label roll in labeler..............................................................................................................39
Adjust product light barrier...........................................................................................................40
Adjust peeler plate .......................................................................................................................41
8.Operation.............................................................................................................43
Safety instructions........................................................................................................................43
Turn on and off labeling machine.......................................................................................43
Operator panel...................................................................................................................44
Turn on labeling operation .................................................................................................44
Stop labeling operation......................................................................................................45
Putting the system out of service.................................................................................................45
9.Maintenance and service....................................................................................46
Safety instructions........................................................................................................................46
Daily servicing (after appr. 8 hours of operation)...............................................................47
Weekly servicing (after appr. 40 hours of operation) .........................................................48
Annual servicing (after appr. 2000 hours of operation)......................................................48
Cleaning notes...................................................................................................................49
Cleaning of sensors .....................................................................................................................50
Safety instructions........................................................................................................................50
Exchange of rollers ......................................................................................................................51
Spare parts ........................................................................................................................51
Safety instructions........................................................................................................................51
Wiring diagram...................................................................................................................51
10.Troubleshooting..................................................................................................52
Safety instructions........................................................................................................................52
Correcting adjustments based on labeler result.................................................................54
11.Index.....................................................................................................................56
12.EC Declaration of conformity.............................................................................57
Chapter 1 General information 40001136 BTA Geset 125
Version: 30.07.14 Page 5 of 57 GB
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 29). Contact our service hotline (page 6); 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 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 40001136 BTA Geset 125
Version: 30.07.14 Page 6 of 57 GB
Purpose and overview of the operating instructions
These operating instructions will help you get to know the system Geset 125 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 40001136 BTA Geset 125
Version: 30.07.14 Page 7 of 57 GB
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 : +49 (0)2224 - 7708 - 440
Fax : +49 (0)2224 - 7708 - 21
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 40001136 BTA Geset 125
Version: 30.07.14 Page 8 of 57 GB
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“
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.
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
Chapter 1 General information 40001136 BTA Geset 125
Version: 30.07.14 Page 9 of 57 GB
Term Explanation
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.
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.
Service unit 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 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
Chapter 1 General information 40001136 BTA Geset 125
Version: 30.07.14 Page 10 of 57 GB
Term Explanation
VDC Direct current voltage.
Water trap See “Service unit“.
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 11 of 57 GB
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.
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 12 of 57 GB
Intended use
The operational safety of the system Geset 125 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 normally laid down in the LSS (Labeling-Systems-Survey) and this document
is handed out to the customer with the order confirmation.
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 equipment is not by-passed or abrogated.
arbitrary changes at the machine are omitted.
the labeling system is used or operated by adequate personnel, refer to “Authorized
persons” (s. page 18).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.
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 13 of 57 GB
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.
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 14 of 57 GB
Hazards to the labeling system
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.
¥Roll conveyor
¥Wrapping unit
¥Labeler
Possible injuries that may be caused by the assembly groups of the labeler, are normally
reversible.
Chapter 2 Safety regulations
40001136 Geset 125
Version: 30.07.14
Page 15 of 57
GB
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.
- If possible, disconnect the power.
- Only electricians may work on the switch cabinet and
electrical 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
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.
ENTANGLEMENT HAZARD!
Rotating elements at the labeling station, like rewinder, driving-
and transport rollers … are driven by a motor.
- Do not grip in, at or between the moving parts.
Hazard from actively controlled movements.
CRUSHING HAZARD!
The movements of the labeling station 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!
Improper handling may lead to health hazards.
- For used lubricants and detergents, the valid information of
the safety data sheets of the manufacturers and the valid
safety- and disposal regulations have to be observed and
followed for each product
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 16 of 57 GB
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.
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 forms
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 exchanging the label web.
*² Risk of injury due to light beam.
RISK OF INJURY!
*² Sensors 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.
Chapter 2 Safety regulations
40001136 Geset 125
Version: 30.07.14
Page 17 of 57
GB
Warnings on the labeling system
Special hazards arising from the labeling system are identified with yellow stickers. The
pictograms indicate hazards:
Danger
Life-threatening hazard due to electrical power
Crushing hazard
Entanglement hazard
*²
Danger due to strong light radiation
Observe manual
*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
mechanisms 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. When connecting the labeler to the customer’s conveying
system, there may arise hazard areas at the transitions. Suitable protection measures
have to be arranged in this case.
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 18 of 57 GB
Obligations of the operator
This manual is a part of the system and has to be available always within reach.
To guarantee a safe operation of the labeling station, the operator is obliged to …
Ensure always the safety for the persons working at the labeling station.
The technical data and information about the installation-, connection-,
surrounding- and operational conditions have to be observed consequently.
The safety regulations that are special for the labeling station are observed.
The use of personal protective gear is observed.
Signposting and marking of hazard areas have to be renewed if damaged or lost.
Personal to be trained or instructed or apprentices work only under constant
supervision of experienced persons.
All work at the electrical equipment is only arranged by qualified Electricians.
All failures at the labeling 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 following persons:
Operators are persons who…
have been instructed to the use of the labeling system.
have completed the minimum age permitted by law.
have read and understood this manual.
Operators are allowed,
to start or stop the labeling operation.
to replace label rolls.
to arrange daily accumulating cleaning works at the labeling system
according to the chaper maintenance.
Qualified personnel are operators who …
have terminated a professional technical training (Electrician, Mechanist).
have terminated a training at the Bluhm-Weber-Group successfully.
Qualified personnel are allowed,
to arrange repair- and maintenance works at the labeling station and its
components according to their professional qualification.
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 19 of 57 GB
Personal protective gear
Wear the following protective gear when working on the machine:
PROTECTIVE FOOTWEAR
To protect against falling parts and slipping.
PROTECTIVE WORK CLOTHES
Protective work clothes fit snugly, tear easily, have tight-fitting
sleeves and no projecting parts.
- Wear a hair net if necessary.
- Do not wear jewelry, wristlets, 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 station and
connect it X X
Put labeling station into
operation X X
Arrange maintenance work X X X X
Ensure product operation X X
Observe the manufacturer's documentation for the
individual components of the machine!
Chapter 2 Safety regulations 40001136 Geset 125
Version: 30.07.14 Page 20 of 57 GB
Protection devices
Operate the system only if all safety- and protection devices are completely available and
functional. Check the protection devices for its function:
At first operation.
At regular routine test.
After exchange of security-relevant components and parts.
If deficiencies occur during operation at the protection devices, stop the system
immediately and remedy the deficiencies! Do not change or remove any protection
devices. Do not take the protection devices out of operation by any change.
Protection devices may only be removed when the system is stopped and safeguarded
against re-starting of the system (e.g. padlock at main switch, disconnect power plug from
power connection). If subcomponents are supplied, the protection devices have to be
installed according to the regulations by the operator.
Connection to the customer’s conveying system may evoke dangerous areas at the
transitions. Suitable safety measures have to be taken in this case.
*² Labeling station‘s cover
The fixed and screwed system covers protect the user against mechanical hazards.
*² 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 system but however the supply in front of the switch can be
energized.
The main switch can be locked in position ”0” as a protection
against a hazard by accidentally or unauthorized switching on
the system.
Lock always the main switch:
During maintenance- and service works.
If switching on the system may lead to a hazard.
*² Emergency-Stop Push Button
Fig. 2-3: Emergency-Stop Push
Button
The emergency stop pushbutton serves for an immediate
stopping of the complete labeling system. It should only be
used in emergency situations. The emergency stop push
button is locked after actuation and has to be locked
manually before restarting (consider the information at the
button).
*² Only if system has the appropriate features.
Table of contents
Other Weber Label Maker manuals
