Weber Alpha HSM User manual

Copyright ©, Weber Marking Systems GmbH
Original instructions
Alpha HSM
Material number of the documentation 40058725
(GB) English
Version: 12.19.17 /OKR
40058725
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: [e-mail]
http://www.webermarking.de

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Content 40058725 BTA Alpha HSM
Version: 12.19.17 Page 3 of 112 GB
Table of contents
1. General...................................................................................................................7
Overview...........................................................................................................................7
Limitation of liability...........................................................................................................7
Warranty conditions...........................................................................................................7
Copyright........................................................................................................................... 7
Purpose and overview of the operating instructions...........................................................8
Notes regarding the operating instructions use..................................................................8
Service Hotline..................................................................................................................9
Explanation of the technical terms used..........................................................................10
2. Safety regulations...............................................................................................14
Behaviour in case of emergencies...................................................................................14
Fundamental safety regulations....................................................................................... 14
Meaning of the risk levels.............................................................................................................14
Intended use ...................................................................................................................15
Reasonably foreseeable improper use............................................................................16
Reconstruction and modification of the labeler................................................................16
Sources of danger on the labeler..................................................................................... 17
Protective devices...........................................................................................................18
Separating and non-separating protective devices......................................................................18
Warning notices on the labeler........................................................................................ 18
Safety instructions........................................................................................................................19
Residual risks.................................................................................................................. 20
Obligations of the operator..............................................................................................21
Approved persons...........................................................................................................21
Personal protective equipment........................................................................................ 22
Workplaces for operating personnel................................................................................ 23
Disposal.......................................................................................................................... 23
3. Technical Specifications ....................................................................................24
Information about other dimensions.............................................................................................24
Performance data.........................................................................................................................25
Information regarding the operation.............................................................................................25
Noise emission.............................................................................................................................25
4. Description of the labeler...................................................................................26
Function and scope of the application ............................................................................. 26
General overview ............................................................................................................27
Module overview ..........................................................................................................................28
Identification of the labeler via the nameplate .............................................................................30
5. Transport .............................................................................................................31
Delivery........................................................................................................................... 31
Scope of delivery..........................................................................................................................31
Transport and Unpacking................................................................................................ 31
Safety instructions........................................................................................................................31
Storage conditions...........................................................................................................33
6. Installation and connection................................................................................34
Safety instructions........................................................................................................................34

Content 40058725 BTA Alpha HSM
Version: 12.19.17 Page 4 of 112 GB
Installation....................................................................................................................... 36
Requirements regarding the installation location.........................................................................36
Positioning of the labeler..............................................................................................................36
Attachment of the labeler.................................................................................................37
Connecting the labeler ....................................................................................................37
Overview of the connections on the labeler.....................................................................38
Connection to the mains voltage..................................................................................................39
*2 Connection an compressed air.................................................................................................40
Connection HMI-Display (X10) ....................................................................................................41
Label sensor connection (optical sensor) (X7) ............................................................................41
Connection label sensor (ultrasonic sensor) (X7)........................................................................43
Product detector connection (X2) ................................................................................................44
Rotary encoder connection (X5) ..................................................................................................45
Alarm lamp connection (X6).........................................................................................................45
USB port.......................................................................................................................................45
Network connection (X20)............................................................................................................45
End of roll warning connection (low label) ...................................................................................46
AUX IN connector (X11)...............................................................................................................47
AUX OUT connector (X12) ..........................................................................................................47
I/O signal interface (X9) ..............................................................................................................48
Signal description.........................................................................................................................48
7. Settings and commissioning .............................................................................49
Safety instructions........................................................................................................................49
Settings........................................................................................................................... 49
Unwinder (Performance)..............................................................................................................50
Adjust the pressure roller.............................................................................................................51
Adjusting the label liner brake......................................................................................................52
Pressure application device setting .............................................................................................53
Loading the label material ............................................................................................... 54
Unwinder (mechanical) ................................................................................................................54
Unwinder (performance and motorized) ......................................................................................55
Label liner brake...........................................................................................................................56
Application....................................................................................................................................56
Drive.............................................................................................................................................57
Rewinder (mechanical) ................................................................................................................57
Rewinder (motorized)...................................................................................................................58
Perform label calibration..................................................................................................59
Initial commissioning....................................................................................................... 61
ZeroDownTime and alternating operation........................................................................62
Description ...................................................................................................................................62
Function .......................................................................................................................................63
Setting the ZeroDownTime / alternating operation ......................................................................63
Twin label mode..............................................................................................................66
8. Operation.............................................................................................................67
Safety instructions........................................................................................................................67
Switching the labeler on/off ............................................................................................. 67
Labeling operation start................................................................................................... 68
Stopping labeling mode................................................................................................... 68
Decommissioning the labeling system............................................................................. 69
Indicator lamps control unit.............................................................................................. 70
Control unit drive module.............................................................................................................70
Unwinder (WAC05) and Rewinder (WAC06)...............................................................................70
HMI display .....................................................................................................................71
Function of the control elements..................................................................................................71
Status LEDs .................................................................................................................................72

Content 40058725 BTA Alpha HSM
Version: 12.19.17 Page 5 of 112 GB
Presentations and operation of the menus..................................................................................72
Password protection.....................................................................................................................73
Menu structure .............................................................................................................................74
Status menu.................................................................................................................... 76
Manual feed .................................................................................................................................77
Temporary setting options............................................................................................................78
“Countdown“ (Set Count Down)...................................................................................................78
Configuration menu.........................................................................................................79
Configuration selection.................................................................................................................79
Speed...........................................................................................................................................80
Trigger delay ................................................................................................................................80
Label position...............................................................................................................................80
Label Length ................................................................................................................................81
Label Gap.....................................................................................................................................81
Labels Burst (Label per trigger) ...................................................................................................81
Label Distance .............................................................................................................................81
Label skip.....................................................................................................................................82
Trigger Blank................................................................................................................................82
Ramp............................................................................................................................................82
Stop ramp.....................................................................................................................................83
Speed control...............................................................................................................................83
Sync Start.....................................................................................................................................83
Sync Length .................................................................................................................................84
Pre Feed ......................................................................................................................................85
Parameter list configuration .........................................................................................................85
Service menu..................................................................................................................86
Automatic label calibration (Teach)..............................................................................................86
Reset Lab. Counter......................................................................................................................87
Event Data ...................................................................................................................................87
Diagnosis (IO-status) ...................................................................................................................88
System menu..................................................................................................................89
Software version (SW-version)....................................................................................................89
IP address....................................................................................................................................89
Gate-Way.....................................................................................................................................89
IP address link..............................................................................................................................90
PLC IP address............................................................................................................................90
Time/date .....................................................................................................................................90
Language .....................................................................................................................................90
Metric / Imperial............................................................................................................................91
Machine parameters ....................................................................................................................91
9. Maintenance and repair......................................................................................92
Safety instructions........................................................................................................................92
Recommended cleaning agents......................................................................................93
Daily maintenance/repair (after approx. 8 operating hours).............................................93
Weekly repair/maintenance (after approx. 40 operating hours) ....................................... 94
Half-yearly maintenance/repair (after approx. 1000 operating hours).............................. 95
Annual repair/maintenance (after approx. 2000 operating hours)....................................95
Cleaning instructions....................................................................................................... 96
Cleaning of sensors .....................................................................................................................97
Cleaning of the deflection rollers..................................................................................................98
Empty the water separator of the compressed air supply............................................................99
Spare parts ................................................................................................................... 100
Safety instructions......................................................................................................................100
Wiring and pneumatic plans.......................................................................................... 100
10. Troubleshooting................................................................................................101
Safety instructions......................................................................................................................101

Content 40058725 BTA Alpha HSM
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Mechanical errors.......................................................................................................... 102
Correct the settings after the labeling result .................................................................. 104
Proper labeling...........................................................................................................................104
Error during the labeling.............................................................................................................104
Error and warning messages......................................................................................... 106
Error acknowledgment...............................................................................................................106
Error messages..........................................................................................................................107
Warnings....................................................................................................................................108
11. Index...................................................................................................................109
Keywords from A to Z.................................................................................................................109
12. Declaration of Conformity................................................................................112

Chapter 1 General 40058725 BTA Alpha HSM
Version: 12.19.17 Page 7 of 112 GB
1. General
Overview
Congratulations, you have chosen to acquire a high-quality labeler. Our aim is to ensure
that you can fully utilize this labeler to your complete satisfaction for many years to come.
To ensure this, we absolutely recommend that the installation (refer to the notice on
page34) be carried out by one of our experienced specialists. Contact our service hotline
(see page 9). We are available to you 24-hours a day from Monday - Friday.
Limitation of liability
All information and instructions in this manual have been compiled taking into account the
applicable standards and rules, the latest technological developments as well as our many
years of know-how and experience.
The manufacturer will not accept any for damages due to:
Non-observance of the operating instructions,
Improper use,
Use of untrained personnel,
Non-approved modifications to the labeler,
Use of spare parts that have not been approved by the manufacturer.
The obligations agreed in the delivery contract, the general terms and conditions of
business as well as the manufacturer's delivery conditions and the statutory regulations
applicable at the time of contract conclusion will apply. We reserve the right to technical
changes and further development in order to improve the performance characteristics.
Warranty conditions
The warranty conditions comply with the general terms and conditions of business of
Bluhm Systeme GmbH valid at the time of purchase.
Copyright
This documentation or parts of the document may only be copied, photocopied,
reproduced or translated into other languages for personal use. Reproduction for
disclosure to third parties is not permitted without prior written consent from Weber
Marking Systems GmbH.

Chapter 1 General 40058725 BTA Alpha HSM
Version: 12.19.17 Page 8 of 112 GB
Purpose and overview of the operating instructions
These operating instructions are designed to introduce the labeler and to facilitate its in-
tended use.
It contains important information for the user to ensure that the labeler is operated safely
and correctly. Their observance helps,
to avoid hazards,
to reduce repair costs and downtime and
to increase the reliability and lifetime of the labeler.
The operating instructions are valid for the labeler specified in the title with the associated
type number.
The operating instructions must be accessible at all times at the place of use of the
labeler. It must be read and applied by the people who are commissioned to work on the
label dispenser.
Printing errors, mistakes and changes in accordance with the latest technological
developments are reserved. For clarification, illustrations can be shown without protective
devices.
Notes regarding the operating instructions use
A detailed explanation of the writing and representation styles used in these operating
instructions is provided below.
Buttons, switches and operating fields that need to be actuated are enclosed in
square brackets.
Example: Press the [Start] button.
Menu items and references to chapters and key words are enclosed in "..."
Example: acc. to chapter "Technical data" on page24.
Operations that must be processed in a fixed sequence are numbered.
Step
Approach
1
Disconnect the mains plug ...
Special information is written in bold and/or with a grey background.
This is an example of special information!
All illustrations (Fig.) are numbered consecutively for each chapter. This means
that a reference to "Fig. 2-1" is equivalent to the 1. Illustration in Chapter 2.
Illustrations are often reduced in complexity to show the essentials. They may
therefore differ from the original. The only reason that covers or protective devices
are not shown in illustrations is to promote better understanding.
Some illustrations are limited to the representation of a certain version (e.g. only
RH, only LH...). This particularly applies when the information content can in es-
sence be applied to other versions.

Chapter 1 General 40058725 BTA Alpha HSM
Version: 12.19.17 Page 9 of 112 GB
Messages which are shown on the display are presented in a box:
Fig.: 1-1 Example for display content
Service Hotline
The technical Service-Hotline is available 24 hours a day from Monday to Friday. In case
of emergencies, a shipment of parts is possible until approx. 6:00 p.m.
Tel : [phone] - 7708 - 440
Fax : [phone] - 7708 - 21
E-Mail : [e-mail]
You will need to have the following information available when you call the hotline in the
event of labeler malfunctions :
Detailed description of the fault
All information from the nameplate of the labeler.
Did the error occur for the first time after the following work step?
oAfter insertion of new label rolls
oAfter making changes to the system configuration.
All information about the state of the PLC signals, in case of a failure of the
application cycle
Before contacting our hotline, we kindly ask you to check whether the operating
instructions (Chapter
"Troubleshooting") do not already provide information to remedy the malfunction.
We aim to maintain the highest degree of availability of our hotline for our customers.
Please understand that our hotline may ask you to apply the written information provided
in the operating instructions.
Status:
Run
Label 89x36 mm
Number: 0
Rest.: 0

Chapter 1 General 40058725 BTA Alpha HSM
Version: 12.19.17 Page 10 of 112 GB
Explanation of the technical terms used
Technical term
Explanation
(Application) stroke
Distance covered by the dispensing tamp when it is extended
towards the product.
Adhesive strips
(Adhesive strips)
Leaked adhesive at the label edge can cause the label to
adhere to the carrier paper. The printed label remains stuck to
the backing paper and cannot be advanced.
Air Assist
A jet of air which presses the label against the bottom of the
tamp / Blow-Box during the feed, until it is held by the vacu-
um.
Air assist tube
(Air Assist Tube)
The Air Assist Tube directs the support air through one or
more holes to the bottom of the label. It is installed in the area
of the peel bar and is adjustable.
Application cycle
Complete cycle of a working sequence of the labeler (e.g.
peel off the label, (if necessary) label transfer to the applica-
tor, all the way up to the labeling of the product).
Application mode
Depending on the equipment, different applicator modes can
be used. See explanations: “Tamp On”, “Tamp Blow”, “Blow
On” and “Wipe On”.
Applicator
Designation for label applicators or mechanical means that
position the dispensing tamp.
Blow-on
Contact-free application mode, during which the dispensing
tamp takes over the printed label through vacuum, and
"blows" it onto the product without repositioning the dispens-
ing tamp.
Blow-on/blow-off air
(Air Blast)
Air that acts on the label at the time of the labelling via holes
in the applicator's tamp plate to dispense the label onto a
product without contact.
Configuration mode
Mode in which parameters for dispenser configuration can be
set in the display.
Contrast
Difference in brightness of the light and dark areas.
Conveying system
Complete system, consisting of the belt conveyor and its con-
troller.
Conveyor belt
Conveyor for the product transport.
Cycle
Sequence of the labeling process, from the product recogni-
tion
through the product labelling, up to the reaching of the
initial position of the dispensing tamp.
Cylinder Home Position Sen-
sor
Sensor for detecting the end position when the cylinder is
retracted.
Dancer arm
Arm that keeps the label liner under tension through spring
force.
Default setting
See “Factory setting”.
Dispensing tamp
See “Dispensing tamp".