Weber Legi-Air 4050E User manual

Original Instructions
Installation, Starting, Operation and Maintenance
Legi-Air 4050E
Article number of documentation 22800998
Copyright ©, Weber Marking Systems GmbH
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: [email protected]
http://www.webermarking.de
Version: 27.01.15 /KRA/ZIM
22800998

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Content 22800998 BTA LA 4050E
Version 27.01.15 Page 3 of 97 GB
Table of Contents
1.General Information..............................................................................................6
Overview ..............................................................................................................................6
Limitation of Liability.............................................................................................................6
Warranty Conditions ............................................................................................................6
Copyright Protection ............................................................................................................6
Purpose and Scope of this Manual ......................................................................................7
Hints for Use of this Manual.................................................................................................7
Service-Hotline.....................................................................................................................8
Explanation of Technical Terms...........................................................................................9
2.Safety Regulations..............................................................................................13
Behavior in Case of an Emergency....................................................................................13
General Safety Regulations ...............................................................................................13
Explanation of Degrees of Danger...............................................................................................13
Intended Use......................................................................................................................14
Reasonably Foreseeable Misuse.......................................................................................15
Retrofitting and Changes at the Labeling System..............................................................15
Sources of Danger at Labeler ............................................................................................16
Labeler without limiting the tamp force to 50N (Legi-Air 4050E-NC…) .......................................16
Warnings on the labeler .....................................................................................................17
Safety instructions........................................................................................................................17
Remaining Risks ................................................................................................................19
Disposal .............................................................................................................................19
Authorized Personnel.........................................................................................................19
Personal Protective Equipment..........................................................................................20
Protection Devices .............................................................................................................21
Separative and non-separative protection device........................................................................21
System Cover...............................................................................................................................21
Emergency Stop Function (only Legi-Air 4050E-NC).........................................................22
Switching Off the Air Pressure .....................................................................................................22
Function of Switching Off the Air Pressure ..................................................................................22
Switching On the Air Pressure .....................................................................................................22
Air Pressure Monitor ....................................................................................................................23
Working Places Operator Personnel..................................................................................23
3.Technical Specifications ....................................................................................24
Information on Further Dimensions..............................................................................................24
Performance Data ........................................................................................................................24
Information on Operation .............................................................................................................25
Noise Level ..................................................................................................................................25
Information on Compatible Print Engine Types ...........................................................................25
4.Description of the Labeler..................................................................................26
Function and Application Field of the Labeler....................................................................26
Complete Overview Legi-Air 4050E...................................................................................27
Figure: Legi-Air 4050E in Righthand Version (RH)......................................................................27
Figure: Legi-Air 4050E in Lefthand Version (LH).........................................................................28
Figure: Legi-Air 4050E Side View (LH/RH)..................................................................................29
Figure: Legi-Air 4050E Rear Side (RH / LH)................................................................................30
Figure: Legi-Air 4050E (TOP) ......................................................................................................31

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Figure: Legi-Air 4050E RFID with Reject-Unit (Option) ..............................................................32
Application Modes..............................................................................................................33
Tamp-Blow-Mode.........................................................................................................................33
Tamp-On-Mode............................................................................................................................33
Blow-On-Mode .............................................................................................................................33
Management of Printing Data ............................................................................................33
Batch Operation (Batch Processing)............................................................................................33
On-Demand Operation (Single Processing) ................................................................................33
5.Transport .............................................................................................................34
Delivery ..............................................................................................................................34
Scope of Delivery .........................................................................................................................34
Transport and Unpackaging...............................................................................................34
Safety Regulations.......................................................................................................................34
Storage Conditions ............................................................................................................37
6.Installation and Initial Operation........................................................................38
Installation..........................................................................................................................40
Requirements to the Site of Installation .......................................................................................40
Placing the Labeler ......................................................................................................................40
Positioning of the Labeler ..................................................................................................41
Connecting the Labeler......................................................................................................41
Overview of the Connections at the Labeler ......................................................................42
Connection to Supply Voltage......................................................................................................43
Connection to Air Pressure ..........................................................................................................44
Connection and Positioning of the Product Sensor .....................................................................45
"Display" – Connection.................................................................................................................46
"Low Label Sensor" - Connection ................................................................................................46
Low Label Warning (Low Label) ..................................................................................................46
"USB" -Interface ...........................................................................................................................46
Applicator" -Connection ...............................................................................................................46
"Alarm Lamp" -Connection...........................................................................................................47
"Printer" -Connection....................................................................................................................47
Print Engine-Setup (Printer).........................................................................................................47
"Interface" (I/O-User Interface).....................................................................................................48
Label and Ribbon Loading .................................................................................................51
Ribbon Loading ............................................................................................................................51
Label Loading...............................................................................................................................51
Initial Operation..................................................................................................................53
Safety Regulations.......................................................................................................................53
7.Operation.............................................................................................................54
Operation of the Labeler ....................................................................................................54
Safety Instruction .........................................................................................................................54
Function of the operator buttons of the remote button box (only Legi-Air 4050E-NC) ................54
Switching ON and OFF the Labeler .............................................................................................54
Start Labeling Operation ..............................................................................................................55
Stop Labeling Operation ..............................................................................................................56
Put System out of Operation..............................................................................................56
Operation of the Display ....................................................................................................57
Functions of the Operator Keys ...................................................................................................57
Status-LEDs .................................................................................................................................58
Program Menus .................................................................................................................58
Indication of Firmware Version ....................................................................................................58
Current Configuration Set ............................................................................................................58

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Label Counter...............................................................................................................................59
Status Line ...................................................................................................................................59
STAND-BY-Mode.........................................................................................................................59
FUNCTIONS-MENU ..........................................................................................................59
Menu-Diagram ...................................................................................................................60
LABEL COUNTER .......................................................................................................................61
RESET LABEL COUNTER ..........................................................................................................61
DISPLAY SETTING .....................................................................................................................62
EVENT COUNTER ......................................................................................................................63
CYCLE SEQUENCE....................................................................................................................64
CONFIGURATION-Menu...................................................................................................65
SELECT CONFIGURATION........................................................................................................65
PASSWORD: 000 .....................................................................................................................66
PRINT TRIGGER: 001..............................................................................................................66
LABEL TIMEOUT: 255..............................................................................................................68
VACUUM LEVEL: 005 .............................................................................................................68
VACUUM TIMEOUT: 200 ..........................................................................................................69
EXTENS.-TRIGGER : 000 ..........................................................................................................69
EXTENSION DELAY: 000...........................................................................................................70
EXTENSION TIME: 080.............................................................................................................71
PROXIMITY TIMEOUT: 000 .......................................................................................................71
BLOW-TRIGGER: 000..............................................................................................................72
BLOW DELAY: 000................................................................................................................73
BLOW TIME: 050..................................................................................................................73
HOME TIMEOUT: 000 ..............................................................................................................74
SYNC PULSE DELAY: 000 ......................................................................................................74
SYNC PULSE TIME : 005.........................................................................................................75
BARCODE RD TIME: 000 ........................................................................................................76
CYCLE OPTIONS: 000.............................................................................................................77
Parameter List of Configuration CFG 0-3...........................................................................78
PROGRAMMING ...............................................................................................................79
DIAGNOSTICS ..................................................................................................................79
Firmware History................................................................................................................80
8.Maintenance ........................................................................................................81
Daily Maintenance (After Approx. 8 Hours of Operation) ............................................................82
Weekly Maintenance (After Approx. 40 Hours of Operation).......................................................83
Six-Month Maintenance (After Approx. 1000 Hours of Operation) ..............................................84
Yearly Maintenance (After Approx. 2000 Hours of Operation) ....................................................84
Spare Parts ........................................................................................................................85
Wiring- and Pneumatic Diagrams ......................................................................................85
Cleaning Notes.............................................................................................................................85
9.Troubleshooting..................................................................................................87
Mechanic Failures..............................................................................................................87
Error Messages by Display ................................................................................................90
Error Reset...................................................................................................................................90
Status Messages via Display .............................................................................................93
10.Index.....................................................................................................................95
Catchwords from A to Z ...............................................................................................................95
11.EC-Declaration of Conformity............................................................................97

Chapter 1 General Information 22800998 BTA LA 4050E
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1. General Information
Overview
Congratulations! You have purchased a high-quality Printer-Applicator. Our concern is to
make sure that you profit from this system to your entire satisfaction over many years. In
order to ensure this, we strongly recommend you to let our experienced specialists
perform the installation (hints s. page 40). Please contact our Service-Hotline (s. page 8).
Limitation of Liability
All pieces of information and notes of this manual have been arranged in consideration of
applicable standards and regulations, state-of-the-art technology as well as our cognition
and experiences over many years.
The manufacturer assumes no liability for damages caused by:
●Non-observance of this manual
●Non-observance of the intended use
●Use of unqualified personnel
●Manipulations at the system
●Use of spare parts that are not approved by the manufacturer
The obligations of the supply contract the General Trading Conditions as well as the terms
of delivery of the manufacturer and the valid legal regulations at the moment of conclusion
of a contract generally apply. Technical changes within the scope of improvement and
development are subject to change without notice.
Warranty Conditions
The warranty conditions are conform to the valid General Trading Conditions of Weber
Marking Systems GmbH at the moment of purchase.
Copyright Protection
This documentation or parts of this documentation may only be copied, photocopied,
reproduced or translated into other languages for personal use. Without previous
expressed written permission of Weber Marking Systems GmbH a reproduction for
circulation to a third party is not permitted.

Chapter 1 General Information 22800998 BTA LA 4050E
Version 27.01.15 Page 7 of 97 GB
Purpose and Scope of this Manual
The Manual is designed to become acquainted with the system and to be able to use the
system according to its specifications.
It provides important remarks for the user to operate the system secure and appropriate.
Its consideration assists to avoid dangers, to reduce repair costs and down times and to
increase the reliability and the durability of the system.
The Manual is valid for the system described in the title with noted serial number.
The Manual has to be available every time at installation site of the system and has to be
read and applied by personnel performing work at the system.
Misprints, errors and state-of-the-art technology changes are subject to change without
notice. Figures may be stated without protection device for clarification.
Hints for Use of this Manual
Detailed explanations are offered below of the conventions for the text and illustrations
which are used in this service manual.
●Buttons and switches that need to be pressed are placed in brackets.
Ex.: Press the [Start] button to accept the changes...
●Procedures that need to be performed in a fixed sequence have to be numbered.
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.
●Some illustrations only show one version (for example, only the right-handed or left-
handed version or only [System1]…), especially when the information is transferable
to other versions.
●Messages that are shown in a *²display, appear in a box:
*² only if system has the appropriate feature
AP4050.0 01234
WAIT LABEL 01

Chapter 1 General Information 22800998 BTA LA 4050E
Version 27.01.15 Page 8 of 97 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 : [phone] - 7708 - 440
Fax : [phone] - 7708 - 21
E-Mail : [email protected]
If failures at the labeling system occur, you should be prepared with following information
when being asked on the phone:
●Detailed error description.
●All information on the name plate of the labeler.
●When did the error occur for the first time?
¥After loading new label material/ribbon?
¥After changes in the setup of the labeler?
●All information about the PLC signals in case of a failure of a print-apply cycle.
Prior to call our hotline service, please have a look at the manual (chapter
"Troubleshooting’’) for potential references to eliminate the error.
Our main effort is to keep the service hotline always possibly free for urgent cases.
However, we beg your pardon that our hotline also refers to written information provided in
this manual.

Chapter 1 General Information 22800998 BTA LA 4050E
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Explanation of Technical Terms
Technical Term Explanation
Adhesive Strings Leaked adhesive at the label edge may adhere the label at
the label liner. The printed label adheres to the liner and can
thus not be fed to the Tamp.
Air Assist A stream of air pushing against the bottom of the Tamp/blow
box during label feed until label is fixed by vacuum.
Air Assist Tube The air assist tube directs air assist by one or more drillings
to the bottom side of the label. It is mounted in the section of
the peeler bar and can be adjusted.
Air Blast The streams of air effusing from the Tamp drill holes during
labeling in order to blow the label by air pressure onto the
product (blow box by tube nozzles).
Application Mode see explanations: Tamp On, Tamp Blow, Blow On.
Applicator Description for label applicator respectively mimic that moves
the Tamp.
Applying Cycle An entire working sequence of the labeler ((e.g. print label if
applicable), peeling off the label and feeding the label to the
applicator up to product labeling).
Bad Tag A "Bad Tag" is a defective transponder of an RFID label. This
tag could not be read and/or written.
Blow-On A contact free application mode in which the Tamp takes the
printed label by a stationary vacuum grid and applies with air
pressure without moving the Tamp.
Configuration Mode Mode, where parameters for applicator configuration can be
changed by display.
Contrast Difference in the brightness of light and dark sections of a
print.
Conveying System Complete unit consisting of conveyor belt and controller.
Conveyor Belt Assembly line for product transport.
CS Abbreviation for conveying system (s. a.).
Cycle Sequence of a labeling procedure, from product detection to
product labeling until the Tamp arrives in home position.
Default See factory setting.
DIP Switches DIP is the abbreviation for „Dual In-line Package“.DIP
switches are tiny switches with 4 to 8 pins. With these pins
the inverter state can be changed (open/closed) by a sharp
object (e.g. pencil). The applicator configuration is determined
by the switch position.
Dancer Arm Arm, tensing the label web via spring tension.
Display Display providing information on status for the user.
Edge Detection The edge (front or back) of a product or label that will cause
the detector to send a detection signal.

Chapter 1 General Information 22800998 BTA LA 4050E
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Technical Term Explanation
Factory Setting
Comprises all basic adjustments of the system after
manufacturing which may differ from the condition after a
system setup. Software parameters are reset by a reset to
the factory setting (default values) and formerly adjusted
values are lost.
Feed (Label Feed) The key [Feed] serves for transportation of a label.
Home Position Basic or home position of the Tamp at the peeler bar.
Home-Position-Sensor Sensor for detection of home position when the Tamp is in
home position.
Hotline Customer support for a fast diagnosis by phone.
Label Applicator Unit for applying labels.
Label Feed Feeding of a label. By pressing the [Feed] key of the print
engine, the drive motor is activated and transport of the label
web is started (dancer arm loosens the unwinder brake
band). The fed label is printed on within the print engine and
peeled off at the peeler bar.
Label Gap Gap between two labels on the label web. The gap is
identified by a sensor on the applicator.
Label Gap Sensor See label sensor.
Label Liner Siliconized liner paper that the labels are affixed to before
they are applied to the product.
Label Out An optical sensor (reflective light sensor) for identifying the
end of the label.
Label Sensor An optical sensor for identifying the label gap.
Label Size Shows the label format width x length (in feed direction of the
label) in mm (millimeter).
Labeler Applicator system to apply labels automatically.
Labeling operation Normal operating conditions. The labeler is ready to print and
apply labels.
Leading Edge The front edge of the product/label that triggers the label
application (see also edge detection).
LED Light Emitting Diode.
Low Label Warning An optical sensor (reflective light sensor) for identifying a
preset minimum of the (adjusted) label roll diameter for a
warning.
Maintenance Unit (FR-
Group)
Unit contains:
Air pressure regulator manometer for displaying the air
pressure value (in bar)
Fast Closing Valve
Water separator for draining the possible present
perspiration water manually
Mandrel A driven axis with a device for fixing the label web. The
mandrel serves for unwinding the label web.