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Chapter 6

Installation and initial startup

40002674 BTA Geset 117

Version: 15.01.14

page 29 of 59

GB

6. Installation and initial startup

Safety instructions

Danger to life from actively controlled movements

.

RISK OF INJURY FROM CRUSHING!

The movements of the labeling system are motor-driven by an
automatic controller (e.g. at infeed spacing unit).

- Maintain a distance from moving parts.

Danger of being pulled in by rotating elements.

DANGER OF BEING PULLED IN!

Rotating elements at the labeling machine, backing rewinder, label
feed, conveyor belt are driven by a motor.

- Do not grip in, at or between the moving parts.

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Summary of Contents for Geset 117

Page 1: ...on and Maintenance Geset 117 Article number of documentation 40002674 Copyright Weber Marking Systems GmbH Weber Marking Systems GmbH Maarweg 33 D 53619 Rheinbreitbach E Mail info webermarking de http www webermarking de Version 15 01 14 OKR 40000465 ...

Page 2: ...Blank Page ...

Page 3: ...beling system 14 Safety instructions 15 Warnings on the labeling system 17 Remaining risks 17 Obligations of the operator 18 Authorized persons 18 Protection devices 20 Labeling station s cover 20 Main switch 20 Emergency Stop Push Button 20 Safety switch 21 Working places for the operator personnel 21 Waste disposal 21 3 Specifications 22 Performance data 22 Information on operator elements 22 No...

Page 4: ...ructions 42 Turn on and off labeling machine 42 Control element 43 Turn on labeling operation 43 Stop labeling operation 44 Putting the system out of service 44 9 Maintenance 45 Safety instructions 45 Daily servicing after appr 8 hours of operation 46 Weekly servicing after appr 40 hours of operation 47 Annual servicing after appr 2000 hours of operation 47 Cleaning notes 48 Cleaning of sensors 49...

Page 5: ...ability 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 regulation...

Page 6: ...ions are offered below of the conventions for the text and illustrations which are used in this manual Buttons switches and pushbuttons that need to be pressed are placed in brackets Ex Press the Start button to accept the changes Menu points and links to chapters and keywords are places in Ex The pushbutton Turning plate infeed outfeed passage Procedures that need to be performed in a fixed seque...

Page 7: ...on 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 t...

Page 8: ...at 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 al...

Page 9: ...iometer 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 Rol...

Page 10: ...Chapter 1 General information 40002674 BTA Geset 117 Version 15 01 14 page 10 of 59 GB Term Explanation VDC Direct current voltage Water trap See Service unit ...

Page 11: ... 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 th...

Page 12: ...stem 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 unadjuste...

Page 13: ...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 de...

Page 14: ...stem 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 Base conveyor Labeler Possible injuries that may be caused by the assembly groups of the labeler are normally reversible ...

Page 15: ...connect 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 DANGER OF BEING PULLED IN 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 ...

Page 16: ...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 Risk of injury due to light beam RISK OF INJURY Sensors or camera illumination may have a strong light intensity Do not look into the source of light Only if system ...

Page 17: ...ining 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 o...

Page 18: ... 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 fo...

Page 19: ...stlets 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...

Page 20: ... the customer s conveying system may evoke dangerous areas at the transitions Suitable safety measures have to be taken in this case Labeling station s cover The fixed and screwed system covers protect the user against mechanical hazards 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 ...

Page 21: ...while labeling When the labeling system is operating without any malfunction the operator may only be in the safe area that is the area covered by the protective measures For servicing repairing and troubleshooting remove the label from the applicator etc the labeling system can be operated from all sides Only one person is permitted to replace the consumable material All interventions are only pe...

Page 22: ...ent temperature 10 38 C Surrounding conditions 20 90 relative air humidity non condensing Performance data Application rate max 100 pieces min depending on product and label size Information on operator elements Operator station 2 pushbuttons main switch Emergency stop emergency stop pushbutton Only if system has the appropriate features Noise level The A evaluated equivalent permanent noise level...

Page 23: ...d manually or by a conveying system provided by the customer at infeed passage of the labeling station Care should be taken on accurate alignment of the products These are held by side guidance on the base conveyor in a row Top side labeling A labeler that is installed above the base conveyor applies the labels in throughfeed on the top side of the product Bottom side labeling A labeler that is in...

Page 24: ... 14 page 24 of 59 GB Complete overview Fig 4 1 Overview of labeling system No Description 1 BASE CONVEYOR 2 SIDE GUIDANCE 3 SWITCH CABINET 4 TOP SIDE LABELER 5 BOTTOM SIDE LABELER 6 AXIAL ADJUSTMENT BOTTOM SIDE LABELER 7 AXIAL ADJUSTMENT TOP SIDE LABELER 8 EMERGENCY STOP PUSHBUTTON ...

Page 25: ...ed check to see if everything is there against the delivery slip Transportion and unpackaging Safety instructions Hazard from lifted loads RISK OF INJURY Falling loads can cause severe injury or death Do not walk under a lifted load The load may not be tilted The location of the center of gravity must be taken into account when transporting the system Hazard from tight straps RISK OF INJURY The st...

Page 26: ...elivered with possible exceptions that is It is standing on a pallet It may be wrapped with stretch film or in a transport box It may be secured with additional straps and the plate feet may be screwed to the pallet Access ways to the machine are sufficiently dimensioned and not blocked Required equipment Suitable means transport double pallet trucks or forklifts with a sufficient lifting force we...

Page 27: ...uhm Weber Group The straps are secured tightly and can fly back when they are cut and cause injury 2 Open if available the transport box applied notes have to be observed Remove any film and straps if available 3 Remove if available all transport securing devices from the rubber feet Fig 5 2 Lift labeling system from pallet 4 Lift the labeling system with a suitable material handling equipment in ...

Page 28: ...tep Procedure 1 Remove the label material from the system 2 Transport the system to its storage location For securing and transporting the labeling system follow the safety instructions in the above section Transportion and unpackaging 3 To protect from dust cover the labeling system with a cotton or paper cloth To prevent the formation of condensate do not use film 4 Climatize the storage locatio...

Page 29: ...nts RISK OF INJURY FROM CRUSHING The movements of the labeling system are motor driven by an automatic controller e g at infeed spacing unit Maintain a distance from moving parts Danger of being pulled in by rotating elements DANGER OF BEING PULLED IN Rotating elements at the labeling machine backing rewinder label feed conveyor belt are driven by a motor Do not grip in at or between the moving pa...

Page 30: ...ine adjustments Requirements at the installation site An enclosed and clean room Flat solid base Any unevenness may not exceed 5 mm when stands from the Bluhm Weber Group are used Sufficient bearing capacity 1 500 kg m Low vibration environment Sufficient lighting 500 Lx No direct exposure to sunlight or a radiator The machine may not be operated within electrostatic or magnetic fields This can ca...

Page 31: ...abeling site maximum distance of 1 5 m as specified in the chapter Specifications on page 22 Required equipment Flat wrench Spirit level If applicable 2 3 persons Instruction Set a labeling system up as follows Step Procedure 1 Move the labeling system to installation site Move labelers without rolls piece by piece diagonally Consider all points for Placing the labeling system on page 30 2 Adjust ...

Page 32: ...witch is in OFF 0 position Power cabling is available Instruction Please connect the labeling system with the power supply as follows Step Procedure 1 Connect the power voltage cable with the power socket Risk of injury from pulling in and crushing Immediately after turning on several system parts make a reference run or move to its home position Maintain a distance from powered system components ...

Page 33: ... RISK OF INJURY FROM CRUSHING The movements of the labeling system are motor driven by an automatic controller in automatic operation Maintain a distance from moving parts Danger of being pulled in by rotating elements DANGER OF BEING PULLED IN Rotating elements at the labeling system like rewinder feed rollers conveyor belt and are powered by a motor Do not grip in at or between the moving parts ...

Page 34: ...s a checklist Requirements Control about product transport One or more sample products Labeling system and if so turning plate are connected to power and Triggering of the labeling system is possible by product sensor or I O interface Only if system has the appropriate features Instruction Please put the labeling system Geset 117 into operation as follows Step Procedure 1 If there are already exis...

Page 35: ...ents of the operator personnel accordingly The base conveyor Pos 1 Fig 7 1 is installed fix The height of the base conveyor can be adjusted by the threads at the rubber feet Pos 4 Fig 7 1 Adjust the base conveyor horizontal via air level Fig 7 1 Base conveyor No Description 1 BASE CONVEYOR 2 FIXING BRACKET BASE CONVEYOR 3 DRIVE MOTOR 4 RUBBER FEET Requirements Power supply is turned off No transpo...

Page 36: ...ustment and initial operation 40002674 BTA Geset 117 Version 15 01 14 page 36 of 59 GB Step Procedure 2 Adjust the height of the base conveyor to the required criteria s section above 3 Tighten again the counternuts ...

Page 37: ...g 7 2 Side guidance No Description 1 STAR GRIP SIDE GUIDANCE 2 SIDE GUIDANCE WITH WEAR STRIP 3 DISTANCE PRODUCT 2 3 mm Requirements Labeling system is turned off 2 sample products No transportation of products Instruction Please adjust the side guidance as follows Step Procedure 1 Loosen the star grips 2 Open the side guidances and place one sample product at beginning and end 3 Adjust the side gu...

Page 38: ... product detection is significant for the positioning of the label onto the product To position the label more backwards onto the product the light barrier could be moved to the rear Labelers with display controller offer the opportunity to process the input signal pf the light barrier after a programmable delay In case of this variant an adjustment of the light barrier is not required It is even ...

Page 39: ...ler plate has to be adjusted on a distance of approx 1 3 mm to the product no product contact via traverse adjustment of the labeler The required label position on the product is adjusted via lateral adjustment of the labeler Fig 7 4 Adjust top peeler plate No Description 1 BASE CONVEYOR 2 PEELER PLATE 3 PRODUCT 4 CLAMPING FOR TRAVERSE ADJUSTMENT 5 CRANK FOR LATERAL ADJUSTMENT Requirements Side gu...

Page 40: ...s 5 Fig 7 4 and adjust the height of the peeler plate according to the required criteria information see above Fix the clamping again 4 Adjust the lateral position to the product via crank Pos 4 Fig 7 4 4 Add more products at the infeed passage to check the adjustment Adjust peeler plate of bottom side labeling The distance between peeler bar and bottom side of product conveyor belt is given const...

Page 41: ...struction Please adjust peeler plate as follows Step Procedure 1 Add a product at the infeed passage of the labeling system Danger of being pulled in Hazards from actively triggered movements Keep away from moving parts 2 Just start the base conveyor and then stop it when the product is in the area of the peeler plate 3 Adjust the lateral position to the product via crank Pos 1 Fig 7 5 4 Add more ...

Page 42: ...ing pulled in by rotating elements DANGER OF BEING PULLED IN Rotating elements at the labeler like label liner rewinder label feed at labeler base conveyor are driven by a motor Do not grip in at or between the moving parts Turn on and off labeling machine Fig 8 1 Main switch on The main switch of the machine located at the switch cabinet s front To turn the machine on turn the main switch to ON p...

Page 43: ...quirements Labeling system is turned off Material rolls at labeling system loaded and threaded Labeling system is connected to power System was put into operation see chapter Installation and initial startup on page 29 Instruction Please turn on the labeling system for operation as follows Step Procedure 1 Turn on the main switch Risk of injury from crushing Hazards from actively controlled moveme...

Page 44: ...use problems with the operation mode This characteristic of the labels as well as the retained curvature depend on the material which can vary significantly between the different print media The ambient conditions such as high temperatures and humidity enhance this effect Remove critical label material before long breaks and after end of work from labeler Instruction Please put the label system ou...

Page 45: ... disposal regulations have to be observed and followed for each product Damages to machines and machine parts Absence or faulty maintenance service and repair work abate the operational availability of the machine This can result in consequential damages and exclusion of warranty claims Machine functions should be monitored continuously Exceptional noise developments or unusual movements e g jerki...

Page 46: ...nt free cloth 21800978 Label remover 21800771 Product recommendation Can be obtained from the Bluhm Weber Group with the eight character article number Instruction Please arrange the daily maintenance as follows Step Procedure 1 Arrange the required maintenance work at the labelers Description s correspondent chapter in provided manual of Alpha 2 Check Base conveyor Product guidings and deflection...

Page 47: ...emover or alcohol 2 Clean all sensors product sensor low label warning sensor label gap sensor carefully with a cloth 3 Examine all pipes connections for tightness and leakage 4 Examine all roller assemblies for free rotation and correct position of the rollers axes Annual servicing after appr 2000 hours of operation Requirements Labeler is without electrical power No transportation of products Re...

Page 48: ...CH LINT FREE CLOTH REINIGUNGSFOLIE LAP SHEET BESTELLANNAHME ORDER PROCESSING TISCHDRUCKER DESKTOP PRINTER ETIKETTIERER LABELER DRUCKMODULE PRINT MODULES ETIKETTIERER LABELER DRUCKKOPF PRINTHEAD GUMMIWALZEN PLATEN ROLLERS SPENDEKANTEN PEELER BARS ANTRIEBSWALZE DRIVER ROLLER FRIKTIONSWALZE FRICTION ROLLER AUF ABSPULERACHSEN UN REWIND MANDRELS STÜTZLUFT EINHEIT AIR ASSIST ASSEMBLY FÜHRUNGSROLLEN GUID...

Page 49: ...nsors and barriers may be damaged when cleaning with compressed air steam cleaner aggressive dissolvers or scrubbing agents Do not use any liquids that may cause short circuits Do not use aggressive dissolvers or scrubbing agents Do not use hard or sharp edged parts for cleaning Maintain the optics of the light sensors and light barriers free of dust and grease Use for cleaning a smooth lintfree c...

Page 50: ...eways 7 Check the distances to other system parts 8 Check the oil and grease lubrication at flange bearings and the drive motor block 9 Oil and lubricate the flange bearings and the drive motor block according to the respective maintenance instructions Cleaning and adjustment of base conveyor Adjust the conveyor belt so that it is centrally clamped All rolls are preferably parallel and right angle...

Page 51: ...rack bed base conveyor and adjacent assembly parts Adjust belt tension The manufacturer s adjustment of the base conveyor does normally not require any adaption If tension or the base conveyor s run have to be readjusted it has to be arranged by experts only Requirements Labeler is without electrical power No transportation of products Instruction Please adjust the belt tension as follows Step Pro...

Page 52: ...m a longer distance that is not influenced by any deflection Requirements No transportation of products Emergency stop pushbutton is unlocked Labeler is connected to power Labeler was put into operation refer to chapter Adjustment and initial operation Instruction Please adjust the belt running direction as follows Step Procedure Risk of injury The examination of the belt running has to be arrange...

Page 53: ... an operational time of 4 5 years After this time it is advisable to exchange the bearing or rollers Spare parts Safety instructions Hazard from incorrect spare parts HEALTH HAZARD Incorrect or faulty spare parts can impair safety and cause injury or damage to the machine Only use original spare parts or parts that are specifically ap proved by the Bluhm Weber Group Wiring diagram The wiring diagr...

Page 54: ... TO LIFE Contact of persons with parts that became live by faults Before performing any work at the labeling station disconnect it from electrical power Hazards from actively controlled movements RISK OF INJURY FROM CRUSHING The movements of the labeling system are motor driven by an automatic controller in automatic operation Maintain a distance from moving parts Danger of being pulled in by rota...

Page 55: ...record Contact supplier of conveying system Label with not suitable adhesive insufficient initial adhesion Change label quality Wrong parameterization Check time and delay settings of the responsible configuration parameters No automatic operation possible The label cannot be applied No trigger of the product sensor Check the incoming trigger signal Countercheck via Enter button The desired rate o...

Page 56: ...ing If the labeling is performed correctly the label is free from creases straight always at the same position on the product No correction is necessary Fig 10 1 Product with correct labeling result Error at labeling The label has creases Fig 10 2 Product with creases in the label Correct the labeling result as follows Step Procedure 1 The application speed of the label may be too fast Examine and...

Page 57: ...position changes from product to product Fig 10 4 Product with position displacement of the label Correct the labeling result as follows Step Procedure 1 The application speed of the label may be too high or too low Correct the application speed of the label 2 Examine and correct the sensor for product detection 3 Examine and correct the distance from peeler bar to product 4 Examine and correct th...

Page 58: ...eler 38 Inspection and maintenance list 47 Installation site 30 Label Feed 8 Label material 44 Label Out 8 Label Sensor 8 lateral adjustment 39 Lateral adjustment 39 40 Light barrier 38 Low Label 9 Maintenance instructions 46 Maintenance list 46 Means transport 26 Operation outdoors 12 Operational safety 12 Operators 18 Outfeed 23 Overview 24 Peeler plate 9 39 Product change 34 Product detector 9 ...

Page 59: ...hat the machine FR Nous déclarons sous notre responsabilité exclusive que la machine Geset 117 DE auf das sich diese Erklärung bezieht folgenden Bestimmungen und Richtlinien entspricht GB to which this declaration relates corresponds to the regulations and directives FR que concerne cette déclaration est conforme aux directives et réglementations suivantes 2006 42 EG 2004 108 EG 2006 95 EG DE Bevo...

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