LABELING MACHINE

INSTRUCTION
MANUAL

SPECIFICATION
Main Drive Motor AC Servo Motor
Dispensing Speed 50 meter/minute
Labeling Output 2-sides 40-100 pcs/min (*depending on product)
Label Size Height- min 20mm / max 230mm
Length-min 20mm / max 300mm
Label Roll Size Max 330mm Diameter
Label Roll Core Size 76mm Diameter
Power Supply 220VAC / 50Hz Single Phase
Compressed Air 4 Bar (for pneumatics wrap around & 3 size rub down)
Conveyer Length 1m – 3m (depending on requirement)
Conveyor Width 3 ¼ inch – 7 ½ inch (depending on requirement)
CM WEIGHING
1 Index

1. Index
2. Important warnings
3. Safety Instructions
4. Introduction
5. Specification
6. Principles of operation
7. Operation Instructions

7.1 Loading the Labels Roll

7.2 Switching On
7.3 Label Stop Position Adjustment (Pre-dispensed length of the labels)
7.4 Label Sensor Sensitivity Adjustment
7.5 Product Sensor Adjustment
7.6 Positioning of the labels on the products (horizontal positioning)
7.7 Transparent Labels for labeling
7.8 Label Holder Disk Brake Adjustment
7.9 Wrap-around Station

8. Spare Part List

9. Troubleshooting
10. Figure

Figure 1: System Components

Figure 2: Power and speed adjustment switches
Figure 3: Label sensor position adjustment
Figure 4: Label pre-dispensed length
Figure 5: Labels sensor sensitivity adjustment
Figure 6: Positioning of labels on products by adjusting the product sensor position
Figure 7: Eye-mark
Figure 8: Labels Holder Disk Brake adjustment
Figure 9: Wrap-around station
2 Important Warnings

Before installing and operating the Automatic Labeling Machine BW 200C read the following
safety instruction:

The labeling machine is exclusively determinate for labeling goods.

For this you have to consider the national specific regulations of:
 Prevention of accidents
 Mechanical stability
 Construction of electrical and mechanical system
 Noise suppression

Take notice of the technical data of the labeling machine. Especially the environment
conditions must be observed.

The operation of the machine must be done by trained personnel.

In case of non-authorized modification, voids the warranty.

Before connecting non-standard product, ask your competent technical supporter.

Never use lubricant on the clutch and break system, this will damage the system.
3 Safety Instructions

Before connecting or disconnecting the labeling machine, please make sure that the
Power is a switch off.

The labeling machine may only be opened by authorized personnel.

While operating the machine, please be aware that letting pinching hair, jewelry, ties,
clothes etc. into the moving parts of the machine i.e conveyer, traction unit might cause severe
injury to the operator.

Only trained personnel can perform the service or repair the machine.
4 Introductions

Automatic Labeling Machine BW 200C is a fully automated label applicator

for universal application. Characteristic feature of the system includes:-
 Low wear and durable
 Compact, easy handling due to modular design system
 Easy operation
 Low maintenance
 Built to suit application
5 Specifications

Operation width 200 mm

Max feeding speed 25 m/min
Labeling accuracy ± 1mm
Minimal Label length 10 mm
Max Label reel diameter 76 mm
Drive Clutch and brake motor
Label core 76 mm
Voltage 220 - 240 AC
Operating Temperature 18 - 50 degree C
Conveyor Optional
Platform / standalone Optional
Wrap-around station Optional
Top stabilizer Optional
6 Principal of Operation

The label web is inserted as shown in figure 5.1. When a product being labeled is
detected by the product sensor , normally a photocell , a signal will be set to the fully
electronic control circuitry of machine. The control electronic will than generate
signal initiate the operation of the electro-magnetic clutch and brake system. The clutch
and brake system is the device controlling the rotary motion of the feed roller. Once the
signal is received from the control electronic, the clutch and brake will allow the
movement of the feed-roller according to the signal received. By deflecting the baking
paper at the dispenser tongue or edge, the label separates and is being applied to the
product by means of a corresponding applicator sponge roller or brush.

The gap or spacing between the labels is detected by a photo-sensor (label sensor). The
electro-magnetic clutch disengages or separate at the same time it engages the electro-
magnetic brake to stop the label. After this the product photo-sensor initiate the next
dispensing cycle.

Figure 1 : Label Rolling Direction

7 Standard Operating Instructions

7.1 Loading the Labels Roll

Load the labels roll as shown in figure 1. Please note that:

1.) Labels stock holder must be firmly tightened.

2.) Make sure that the tension of the label-web is good. Not too tight not to loose.
Labels-web must be threaded in between the label-sensor for label gaps
Detection. Failing to which will caused the labels being dispensed continuously.

3.) Label-web side edges must be straight or parallel to the applicator-head, left or
right side of the deflecting plate (tongue) so that the labels will not be slanting
when it is being labeled onto the product.

7.2 Switching On

1.) Select “Auto” and Press “Start” button on touch screen

2.) Select “Station A “ for left side label sticker

“Station B “ for right side label sticker
Or both for double sticker

3.) Trigger the product-sensor manually to ensure that only one label is dispensed
each time the sensor is triggered.

4) Select “Belt Conveyor Run” and Chain Conveyor Run On.

7 Standard Operating Instructions

Main Menu

Speed control for respective conveyor and motor

7 Standard Operating Instructions

To select Servo Motor over run

- To select press “Fine tune off” then press desired status. (recommend to run in “normal “ for papersticker”
-

Monitor Encoder running status

7 Standard Operating Instructions

7.3 Label Stop Position Adjustment (Pre-dispensed length of the labels)

1.) The position of the label sensor determines the label stop or the pre-dispensed
label length. Referring to figure 3, adjusting the position of the label sensor to adjust the
label
stop / pre-dispensed label length

2.) Recommended pre-dispensed label length is 2-4mm from dispensing plate

edge. (figure 4)

Figure 3 : Label sensor sensing adjustment

7 Standard Operating Instructions

Figure 4: label pre-dispensed length

7.4 Label Sensor Sensitivity Adjustment

1.) Label sensor controls the start and stop of the label. If label sensor is not adjust
properly / not detecting the label gaps, the label will dispensed continuously.

2.) Label sensor consists of a transmitter and receiver.

3.) Status of label sensor LED indicator.

a.) No load (no label web)

– Both red LED ‘on’. Green LED ‘on’
b.) Detect labels
– Label Detected- Transmitter red LED ‘Off’
˗Label Gap Detected – Transmitter red LED ‘On’

4.) Green LED should remain ‘On’ during the entire transition.

If the above condition do not exist, please use a fine screw driver to fine adjust
the adjustment dial found on the sensor. The adjustment must be carried out so that the above
mentioned status are met for labels and gaps.
7 Standard Operating Instructions

Figure 5: Labels sensor sensitivity adjustment

7.5 Product Sensor Adjustment

1.) Fiber-option photocell is use as the product sensor.

2.) The status of the product sensing is shown in the amplifier unit.
-No product detected - RED LED ‘Off’
-Product detected - RED LED ‘On’

3.) If the above mentioned statuses are not met during the product sensing / no label
dispensed, put the product in front of the fiber-optics, press and hold the set
button on the amplifier. The light on the amplifier should start blinking. Release
the button when the blinking stops. Test with a product to verify the setting
7 Standard Operating Instructions

7.6 Positioning of the labels on the product horizontal positioning

1.) In case where the labels are not applied at the position as per required
(horizontal), the location of the product sensor should be adjust along the
guide i.e left / right to obtain the proper position.

Figure 6: Positioning of labels on products by adjusting the product sensor position

7 Standard Operating Instructions

7.7 Transparent Labels for labeling

When transparent labels (e.g transparent PE / PVC / Polyolefin etc.) are used for
labeling using the Bosspack Automatic Labeling Machine WR150C2, the label must
be follow the specification below:

1.) The eye-mark printed on the label web must be at least 10mm x 10mm in
dimension and very dark black in colour, so that the label sensor can detect
stably.

2.) If eye-marks are printed on the transparent labels, the design of the label must
not interfere with eye-mark. In other words, the passage of the eye-mark to
the label photocell must be clear of any other design printer on labels.
Otherwise, the detection of the eye-mark will never be accurate.

Figure 7: Eye-mark
7 Standard Operating Instructions

7.8 Label Holder Disk Brake Adjustment

The label holder disk must be able to rotate freely on its own when the machine is in
operation or labeling.

A slight braking rotation is required by the brake-belt so that label-web can be

delivered with due tension.

However, too much braking friction is not applicable as it might snap the label web
or labeling inaccuracy might occur.

Adjust the optimum tension required with the adjusting knurl nut provided.

At the same time push the tension roller up and down to located the right braking
friction required. Refer to figure 8 for the location of the knurl nut.

Figure 8: Label Holder Disk Brake adjustment

7 Standard Operating Instructions

7.9 Wrap-around Station

For specific application, i.e. to label round product as bottles, a wrap-around station
is required in order to wrap the label around the bottle. Figure 9 shows a typical
wrap around station.
There are 2 switches related to the wrap-around station:

a.) “On” button which is normal integrated into conveyed where the wrap-around station
will be switched on along with the conveyer.
b.) Rotation Speed Adjustment dial. The speed of the wrap-around has to be
adequate to avoid wrinkled labels on the product. This can be achieved by
adjusting the speed of the wrap-around station.
Refer figure 2 for the exact location of the switches.

Figure 9: Wrap-around station

8 Spare Parts List

SPARE PARTS LIST

8 Spare Parts List

8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
8 Spare Parts List
9 Troubleshooting

Troubleshooting
Symptom Diagnosis Action
Change the standard roll against
Labels peel off at the label roll Label roll diameter is too small
a roll with enlarge diameter
Label Sensor cable id broken Replace
IR Transmitter cable is broken Replace
IR transmitter LED broken Replace transmitter print
Label sticks below the label Remove and clean sensor
Labels dispensed continuously
sensor
IR light guide is blind Replace
Label sensor position not over Place the sensor to the correct
the label position
Labels are not dispensed straight Peeling bar at the tongue / Replace
forward deflector edge is worn out
Labeling speed too fast Reduce the conveyer speed
Labels form bubbles
Wrap around speed too slow Reduce wrap-around speed
Labeling speed too slow Increase labeling speed
Wrap around speed too slow Increase wrap-around speed
Labels form wrinkles
Labeling machine is misalign to Realign the machine
product path
Lateral paper guides hurts the Enlarge the space between the
paper web paper guides
Label web breaks behind the Use peeling bar with bigger
peeling bar of the tongue / Peeling bar is too sharp radius / add Teflon tape around
deflector plate the peeling bar
Lift the labeling machine /
Peeling bar touches the product
tongue away from the products
No power supply Check fuse / supply
Conveyer not running
Dead conveyer motor Replace
The main fuse the often blows The main impedance too low Use an extended power cord
LABEL ROLL

LABEL SENSOR

LABEL DEFLECTOR
(TONGUE)
LABEL

LABEL! WEBS
LABEL WASTE
REWINDER 3D VIEW
Title
LABELING MACHINE
CMWEIGIDNGPI'ELID Description:
8Y81EM co..oNENl8

Drawn: AZROY Data: 27.IJll.2011 Material: 8l8'TEB. ALL DIM. ARE IN MM

Checked: NtlCEE Projection Quantity: 1 PCS Drawing No:
Approved: Llot Tolerance: .x :I0.100
JO( :l:O.OIIO
Scale: N.T.8 JOCX :IO.G10
JQQCX :I0.111111 Revision
 PLAN VIEW

LABELING MACHINE
CM WEIGHING SDN BHD
3D(LEFT) VIEW DIRECTION STICKER

ILHAM 15/03/2012 -

LIM 1 UNIT

LIM
[ -
[[
[[[
N.T.S [[[[
 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21
SCHMATIC MAIN INCOMING
DRAWING 415VAC 60Hz 3 PHASE
01 02 03
E

MCB1
TITLE:

CLIENT:

20A
L L1
Labeling Machine

N N1

MCB2
20A
L2 03
N2 04
MCB3
20A
L3 05
N3 06
CHECK:
DRAWN:K F LIM

PTE LTD
CM WEIGHING

L N
PS01 E
2.1A
+ -
FILE:

DATE:
DRAWING NO:
SCALE:

FAN
To Relay
24VDC

0VDC
lM/1/1005/09

06/06/2009

08 09
NTS

TO
RELAY,
TOUCH
SCREEN &
SHT:

VALVE
01
 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21
SCHMATIC
DRAWING

L1 L2
N1 N2
TITLE:

CLIENT:

E E
Labeling Machine

M0

GND
L1
L2
L3
L1
L2
L3

M0

GND

L1
L2
L3

L1
L2
L3
2FI1 VFD-E 2FI4 VFD-E 2FI2 ASDA-A2 2FI3 ASDA-A2
8 1 8 1
U
V
W
CHECK:
DRAWN:K F LIM

PTE LTD
CM WEIGHING

10 11 10 11

U-2
V-2
W-2

U-3
V-3
W-3

U-4
V-4
W-4
U-1
V-1
W-1

4 A White/Green 4 A White/Green
5 B Blue 5 B Blue

Top Motor
Slat Chain Conveyor Labeller motor1 Labeller motor 2
FILE:

DATE:
DRAWING NO:
SCALE:

0.75 Kw
0.75 Kw 0.75 Kw 0.75 Kw
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06/06/2009
NTS

SHT:
02
21
20
19

Y05
Y04
18

Y03
Y03
17

C1 Servo Off
16

.
15

Y02
Y02

Home Mode
14

Y01
Y01

B DI7- Servo Motor

13

Y00
Y00

A DI7- Servo Motor

12

C0
11
10

X07
PLC CPU MODULE
09

X06
08

X05
X04
07

3s1

X03
X03

In Sensor Line B
06

3s1

X02
X02

In Sensor Line A
05

2 3sw1 2 3sw2

X01
X01

Stop
1
04

X00
X00

Start
1
03

S/S
02

08

24VDC 07
01

0VDC
00

CLIENT: DATE: 06/06/2009

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DRAWING NO:
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SCHMATIC
DRAWING

lM/1/1005/09

TITLE: DRAWN:K F LIM FILE: SHT:

Labeling Machine CHECK: SCALE: NTS 03
21
20
19

Main Panel
Main Panel
Tag Name No.
18

Conn. No. No. Tag Name

L 01
DI4- Digital Input ACN1-08 101 Y2 (Home Mode)
N 02
DI1- Digital Input ACN1-09 102 Eye Mark Sensor
L2 03
17

DI2- Digital Input ACN1-10 103 Y3 (Servo Off)

L2 03
COM+ Power Input (12-24V) ACN1-11 104 24VDC
L2 03
OA Encoder A Pulse Output ACN1-21 105 0A
N2 04
16

/OA Encoder /A Pulse Output ACN1-22 106 /0A

N2 04 To B Servo unit Conn.5
/OB Encoder /B Pulse Output ACN1-23 107 /0B
N2 04
OB Encoder B Pulse Output ACN1-25 108 0B
L3 05
15

DI7- Digital Input ACN1-31 109 Y0 (photo sensor)

L3 05
COM- VDD (24V) power ground ACN1-49 110 0VDC
N3 06
14

N3 06
E 07
E 07
13

E 07
24VDC 08
24VDC 08
Main Panel
12

24VDC 08
Conn. No. No. Tag Name
24VDC 08
DI4- Digital Input BCN1-08 201 Y2 (Home Mode)
0VDC 09
DI1- Digital Input BCN1-09 202 Eye Mark Sensor
11

0VDC 09
DI2- Digital Input BCN1-10 203 Y3 (Servo Off)
0VDC 09
COM+ Power Input (12-24V) BCN1-11 204 24VDC
0VDC 09
DI7- Digital Input BCN1-31 205 Y1(photo sensor)
10

T+ 10
COM- VDD (24V) power ground BCN1-49 206 0VDC
T- 11
09
08
07

Main Panel
Tag Name No.
ACN3-05 BCN3-05 A 301 RS485+
06

ACN3-06 BCN3-06 B 302 RS485-

05
04

Orange/Red
Encoder Code

White/Red

Black/Red
03

Orange
Brown
White
Black

Blue
02

Opt_/B

Opt_/A
Opt_/Z

Opt_B
Opt_A

Opt_Z
GND
GND
+5V
01

Pin No.
1
2
3
4
5
6
7
8
9
00

CLIENT: DATE: 06/06/2009

CM WEIGHING DRAWING NO:
PTE LTD
SCHMATIC
DRAWING

lM/1/1005/09

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Labeling Machine CHECK: SCALE: NTS 04
21
Main Panel
Conn. No. No. Tag Name
Servo Encoder Code
20

CN2 Pin
BCN1-08 201 Y2
5 T+ Blue
BCN1-09 202 EYE MARK
4 T- Blue/Black
BCN1-10 203 Y3
-
19

Reserved
BCN1-11 204 24VDC
Reserved -
BCN1-31 205 Y1
14,16 +5V Red/White
BCN1-49 206 0VDC 45,47,49
13,15 GND Red/White
18
17
16

Servo motor Line B

C
N
1

C
N
2
Red
15

-C108-04-ES
C
N
White

4
C
N
3
V
ASDA-A2

Black

C
N
W
-0423-U

ECMA
14

Green
E

C
N
C
N

7
5
13

24Vdc
12

Com. 2
R+,T+
0Vdc

R-,T-
Main Panel
11

Tag Name
Encoder

Conn. No. No. Tag Name

A
B
ACN1-08 101 Y2

AS38BSTD
ACN1-09 102 EYE MARK
10

ACN1-10 103 Y3 ACN3-06 BCN3-06

ACN3-05 BCN3-05

ACN1-11 104 24VDC

ACN1-21 105 0A Black (pin4)
09

to B-CN5

ACN1-22 106 /0A Blue (pin5)

Blue/Black

Red/White
Red/White
Servo Encoder Code
ACN1-23 107 /0B Red (pin2)
ACN1-25 108 0B White (pin3)
08

Blue
ACN1-31 109 Y0
ACN1-49 110 0VDC 45,47,49

GND
T+
07

T-

+5V
-
-
Reserved
Reserved
CN2 Pin

14,16
13,15
06

5
4
Orange/Red
Encoder Code

White/Red

Black/Red
05

Orange
Brown
White

Servo motor Line A

Black

C
N
1

C
N
2
Blue

Red
U
04

-C108-04-ES
C
N

White
4
C
N
3

V
ASDA-A2
Opt_/B

Opt_/A
Opt_/Z

Opt_B
Opt_A

Opt_Z

Black
GND
GND

-0423-U

C
N
+5V

W
6

ECMA

Green
E
03

C
N
C
N

7
5
Pin No.
1
2
3
4
5
6
7
8
9
02

ES-25LN8542
01

Encoder
00

CLIENT: DATE: 06/06/2009

CM WEIGHING
DRAWING NO:
PTE LTD
SCHMATIC
DRAWING

lM/1/1005/09

TITLE: DRAWN:K F LIM FILE: SHT:

Labeling Machine CHECK: SCALE: NTS 05