Weber 4300 User manual

Model 4300
Printer-Applicator
User’s Manual
Copyright 2012 Weber Packaging Solutions, Inc.
This documentation contains confidential information and
trade secrets of Weber Packaging Solutions, Inc. and its suppliers.
Version 1.0
Weber Packaging Solutions, Inc.
711 W. Algonquin Road
Arlington Heights, IL 60005-4457
Phone: [phone] Fax: [phone]
www.weberpackaging.com
05/2012
Item Number 56121

Weber Packaging Solutions, Inc. i
Contents
1 Introduction.........................................................................................................1-1
Purpose and Scope of this Manual......................................................................1-1
Conventions Used in this Manual........................................................................1-1
Manual Outline....................................................................................................1-3
Customer Support...............................................................................................1-4
2 General Information............................................................................................2-1
Specifications......................................................................................................2-1
Where to Put the Machine...................................................................................2-2
Safety and Machine Reliability Considerations...............................................2-2
Machinery Directive 2006/42/EC ....................................................................2-2
Safety Guarding..............................................................................................2-2
Stop Function.................................................................................................2-2
Pneumatic Power Supply Failure ........................................................................2-3
Machine Layout and Components.......................................................................2-5
3 Preliminary Setup ...............................................................................................3-1
Printer-Applicator Unpacking, T-Base Mounting, Moving, and Transporting........3-2
Unpacking and T-Base Mounting the Printer-Applicator..................................3-2
Moving and Transporting the Printer-Applicator..............................................3-4
Ribbon and Label Loading ..................................................................................3-5
Ribbon Loading ..............................................................................................3-5
Label Loading.................................................................................................3-6
Label Width Setting ........................................................................................3-6
Tamp Pad Setup.................................................................................................3-7
Overview ........................................................................................................3-7
General Information........................................................................................3-7
Punching Instructions and Safety ...................................................................3-7
Tamp Blow Configuration ...............................................................................3-8
Tamp Blow Flag Configuration......................................................................3-10
Air Filter Setup..................................................................................................3-11
4 Applicator Setup.................................................................................................4-1
Connection to AC Power.....................................................................................4-1
Compressed Air ..................................................................................................4-2
Compressed Air Connection...........................................................................4-2
Air Assist Adjustment......................................................................................4-2
Tamp Home Adjustment......................................................................................4-3
Tamp Pad/Label Alignment.................................................................................4-5

Contents
ii Printer-Applicator User’s Manual
Vacuum and Air Assist Regulator Adjustment.....................................................4-7
Tamp Adjustment...........................................................................................4-9
Air Blast Adjustment .........................................................................................4-11
Static Stack Test...............................................................................................4-12
Low Label Sensor Adjustment ..........................................................................4-15
Low Label Sensor Functionality....................................................................4-15
Low Label Sensitivity Adjustment.................................................................4-16
Low Label Sensor Trigger Point...................................................................4-18
Machine Attitudes.............................................................................................4-19
Rotatable Display..............................................................................................4-21
5 Product Detector Setup......................................................................................5-1
Positioning the Applicator ...................................................................................5-1
Product Detector Sensitivity Setup......................................................................5-1
Product Detector Position ...................................................................................5-2
Test Run........................................................................................................5-2
6 Controller Operation ..........................................................................................6-1
Applicator Menu Flowchart .................................................................................6-1
Controller Keypad...............................................................................................6-3
Setup Menu....................................................................................................6-4
Set Options....................................................................................................6-4
Active Edge....................................................................................................6-5
Set Language.................................................................................................6-5
Set Timers......................................................................................................6-5
Set Run Mode................................................................................................6-7
Diagnostics Screen.............................................................................................6-8
View Inputs ....................................................................................................6-8
Test Outputs ..................................................................................................6-9
Cycle Time.....................................................................................................6-9
Test Cycle......................................................................................................6-9
Return Button .....................................................................................................6-9
7 Maintenance........................................................................................................7-1
Daily Maintenance..............................................................................................7-1
Weekly Maintenance ..........................................................................................7-2
Six-month Maintenance......................................................................................7-3
Yearly Maintenance............................................................................................7-4
Tamp Home Sensor Adjustment.........................................................................7-5
Rewind Flag and Sensor Adjustments................................................................7-6
8 Troubleshooting.................................................................................................8-1

Contents
Weber Packaging Solutions, Inc. iii
9 Appendix.............................................................................................................9-1
Product Detector Jumpers...................................................................................9-2
JMP2 Settings................................................................................................9-3
Stack Light..........................................................................................................9-4
Stack Light Color Code...................................................................................9-4
Weber Circuit Stack Light Specifications ........................................................9-4
External Tamp Disable Switch.............................................................................9-5
I/O Interface....................................................................................................9-6
I/O Connector Pin-out.....................................................................................9-6
Inputs Specifications.......................................................................................9-7
Trigger Apply..................................................................................................9-7
Trigger Print....................................................................................................9-7
Trigger Signal Usage ..........................................................................................9-8
Start 9-8
Applicator Disable...........................................................................................9-8
Input Connection Examples ................................................................................9-9
Outputs Specifications.......................................................................................9-10
Ready 9-10
Tamp Home..................................................................................................9-10
Label-On-Pad...............................................................................................9-10
Warning9-10
Tamp Error...................................................................................................9-10
Data Ready ..................................................................................................9-10
Output Connection Example.........................................................................9-11
AC Wiring..........................................................................................................9-12
DC Wiring..........................................................................................................9-13
Redundant System Feature (aka Zero-Downtime) ............................................9-14
Pneumatic Schematic .......................................................................................9-15
Center of Gravity Drawings ...............................................................................9-16
CE Declaration of Incorporation ........................................................................9-18
CE Declaration of Conformity............................................................................9-18
10 Warranty..........................................................................................................10-1
Weber Warranty Statement 4300 Applicator .....................................................10-1
Limitation of Liability..........................................................................................10-1
11 Index................................................................................................................11-1

Contents
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Weber Packaging Solutions, Inc. v
Glossary
Adhesive String:
Label adhesive that adheres to the label and the label liner while the label is dispensing. It can
cause the label to be improperly positioned on the tamp pad.
Air Assist:
The stream of air the air assist tube directs at the label to help it break free from the label liner
as it is dispensing.
Air Assist Tube:
A small tube located at the end of the peeler bar that directs a stream of air at the label in order
to help it break free from the label liner as it is dispensing.
Baud Rate:
The maximum rate of data transmission (in bits per second).
Continuous:
Products are not required to trigger a label application; completion of label printing triggers
label application.
Cycle Time:
The amount of time that it takes the machine to perform a complete machine sequence, starting
from the detection of the product.
Edge Detection:
The edge (front or back) of a product or label that will cause the detector to send a detection
signal.
Ganged Configuration:
A method for wiring together grouped applicators.
LED:
Light Emitting Diode
Label Feed:
The process for feeding the label stock through the machine.
Label Liner:
Backing paper the labels are affixed to before they are applied to the product.
Label Sensor:
The photoelectric sensor (pitch detector) that detects the presence of a label in the machine.
Label Size:
The length and width of the label. Length refers to the distance from the leading edge to the
trailing edge in the feed direction. Width refers to the measurement of the label perpendicular to
the length.
Label Stock:
The label liner with labels still attached.

Glossary
vi Printer-Applicator User’s Manual
Leading Edge:
The first edge of the product that triggers the label application.
Lock Pin:
The metal piece that secures the label liner to the rewind mandrel.
Machine Sequence:
The sequence in which the machine executes all the steps necessary for a complete cycle.
Mandrel:
A shaft that can spin on its axis, on which another device is mounted.
Operating Mode:
The Printer-Applicator operates in Tamp-Blow Mode.
PSIG:
A measure of air pressure (Pounds per Square Inch Gauge). 1 bar = 14.7 PSI.
Parity:
A data bit that provides a means of checking for errors in the data stream.
Pneumatic:
Moved or operated by air pressure.
Product Delay:
The time delay before extending the tamp and firing the air blast to apply a label.
Product Detector:
A photoelectric device that detects the presence of a product edge and sends a signal to the
applicator controller.
Repeat Length:
The distance between the leading edge of one label to the leading edge of the next.
SCFM:
A measure of volume (Standard Cubic Feet Per Minute).
Static Stack:
A stack of labels that have been applied one on top of the other. When the applicator is setup
correctly, a static stack will have less than + or –1/16 of an inch variation in any direction.
Tamp:
A mechanical device that receives a printed label and moves the label to a position where it is
applied to a product.
Tamp Blow Mode:
Mode in which the tamp remains in the retracted position until an apply signal is received. Upon
receipt of an apply signal, the tamp extends, the air blast applies the label, and the tamp retracts
to receive the next label. Tamp Blow mode is most suitable for operations requiring the tamp to
reach into a recessed area on the product.
Tamp Retract Mode:
Mode that determines whether the tamp retracts at the start or the end of an air blast.
Trailing Edge:
The trailing edge of the product triggers label application.
VAC:
Volts AC (Alternating Current). Also designated as [~].

Glossary
Weber Packaging Solutions, Inc. vii
Vacuum Generator:
A device that uses compressed air to create vacuum.
VDC:
Volts DC (Direct Current).
Web:
The label liner with labels still attached that feeds into the machine.

Glossary
viii Printer-Applicator User’s Manual
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Weber Packaging Solutions, Inc. 1-1
Overview
1
Introduction
The Weber Model 4300 Printer-Applicator incorporates a label printer
within a label applicator. The applicator is designed to accommodate
different types of print engines. For print engine operation, refer to the
manufacturer’s Print Engine Manual for moreinformation. This
chapter covers the purpose and scope of this manual, the conventions
used to convey information and the manual outline. Customer Support
information is located at the end of this chapter.
Purpose and Scope of this Manual
This User’s Manual is designed for users who will be performing the following tasks:
Machine installation
Machine setup and configuration
Machine operation
Machine troubleshooting and maintenance
This manual is designed to provide procedures and reference material needed to complete the tasks
mentioned above. All operators should be familiar with the conventions and guidelines outlined below
before performing any of these procedures.
Conventions Used in this Manual
Following is a brief list of the conventions used in this manual:
A pointing hand symbol indicates special notes and warnings:
 NOTE: This is a special note.
Keys that you must press on the machine appear in a special boxed font:
Set the [POWER ON/OFF] switch to the OFF position.

Chapter 1
1-2 Printer-Applicator User’s Manual
Procedures that should be followed in a specific order are listed in numbered paragraphs:
Disconnect the applicator from the AC power source.
References to other section names appear in bold text:
For more information, see Chapter 5, Product Detector Setup.
Messages that appear on a machine screen are shown in a box using bold Univers typeface:
WEBER MODEL 4300
(c)2012

Pay special attention to any procedure that may have one of the following symbols. Read all of the
Caution and Warning instructions and follow them when performing the corresponding procedures.
CAUTION
THIS SYMBOL IS USED TO WARN USERS OF DANGER FROM (POSSIBLE)
ELECTRICAL SHOCK! READ ALL CAUTION STATEMENTS AND FOLLOW
ALL THE INSTRUCTIONS TO AVOID A PERSONAL INJURY AND/OR
EQUIPMENT DAMAGE.
CAUTION
THIS SYMBOL IS USED TO WARN USERS THAT THERE IS A DANGER OF
BEING INJURED BY WORKING PARTS OF THE APPLICATOR! READ ALL
CAUTION STATEMENTS AND FOLLOW ALL THE INSTRUCTIONS TO AVOID
A PERSONAL INJURY AND/OR EQUIPMENT DAMAGE.
NOTICE
THIS SYMBOL IS USED TO WARN USERS THAT MACHINE DAMAGE IS
POSSIBLE IF ALL PROCEDURES ARE NOT FOLLOWED CAREFULLY. READ
ALL NOTICE STATEMENTS AND FOLLOW ALL THE PROCEDURES
CAREFULLY IN ORDER TO AVOID EQUIPMENT DAMAGE.

Introduction
Weber Packaging Solutions, Inc. 1-3
Manual Outline
Chapter 1. Introduction
Defines the purpose and scope of this manual. Explains
the conventions used within the manual and lists an
outline of the material covered. Includes customer support
information.
Chapter 2. General Information
Includes specifications for proper air and power sources,
information regarding machine placement, and drawings
that illustrate the machine layout and identify key
components.
Chapter 3. Preliminary Setup
Includes all the procedures that can be done before the
AC power and compressed air are connected to the
machine.
Chapter 4. Applicator Setup
Covers the setup procedures for the label applicator.
These procedures include label and tamp adjustments,
and air pressure settings. It also includes operational tests
and alarm conditions.
Chapter 5. Product Detector Setup
Covers the Setup and adjustment procedures for the
product detector. It also explains how to position the
applicator and adjust its sensitivity.
Chapter 6. Controller Operation
Describes the controller's functions and explains how to
use the control panel to adjust the applicator.
Chapter 7. Maintenance
Details instructions for performing maintenance on the
Model 4300 Printer-Applicator.
Chapter 8. Troubleshooting
Covers diagnostic and troubleshooting information.
Chapter 9 Appendix
Setup and operation of optional accessories and technical
specifications.
Chapter 10. Warranty
Applicator warranty statement.
Chapter 11. Index
Alphabetical listing of sections/topics.
NOTE: For information about the print engine, refer to the manufacturer’s manual.
NOTE: The Glossary is after the Table of Contents.

Chapter 1
1-4 Printer-Applicator User’s Manual
Customer Support
Technical support representatives are available 7:00 AM to 5:00 PM CT Monday through Friday.
Call 1.800.323.9519

Weber Packaging Solutions, Inc. 2-1
Overview
2
General Information
This chapter describes general functional and logistical information
regarding the machine and its use. This includes air and power source
specifications, pneumatic safety, recommendations for machine placement,
and illustrations of machine layouts and components.
Specifications
Dimensions (W x D x H)
28.92 x 27.49 x 24.5” (73.45 x 69.82 x 62.23 cm)
Weight
180 lbs (82 kg) *
Electrical
Refer to the nameplate on the applicator for specific
voltage and amperage requirements.
Compressed Air Requirements
Compressed Air Consumption
(applying a 4x6” label with a 3.00”
stroke at 40 labels per minute
Air must be clean (i.e., free of solvents, oxidizing
agents, corrosive materials, and organic matter) and
dry (i.e., free of water and lubricants).
Filter must be drained periodically (see Chapter 7,
Maintenance).
4.6 SCFM ** @ 110 psi
Level of Noise Emission in
accordance with ISO 4871
Sound pressure level LpA (referenced 20 µPa)
measured at the operator’s station: 70 dB
Uncertainty KpA: 1 dB
Environmental
Temperature 41–104° F (5–40°C)
Humidity 15–85% RH non-condensing
* Model 4300 with Zebra 170PAX4 printer, u-arm, 3.0” stroke, 6”x 4” tamp pad, and air filter:
159lbs; Full supply roll of Weber label L-6306: 21lbs.
** SCFM = standard cubic feet per minute based on the following conditions: 14.7 psia, 60° F,
and 0% relative humidity

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2-2 Printer-Applicator User’s Manual
Where to Put the Machine
If the printer-applicator (P/A) is installed on a machine stand, it must be able to support up to 180 pounds
(82 kg) and have a base that is large enough to prevent the machine from tipping over.
When positioning the machine consider the following placement criteria:
Position the machine an appropriate distance away from the product for proper labeling.
When retracting, the tamp must not touch any part of the product as it passes the machine.
The position of the machine must allow the operator to easily change labels and ribbon,
and reach the printer keypad.
Safety and Machine Reliability Considerations
Do not operate the machine in an environment where flammable or explosive gases are
present.
Do not operate the machine in direct contact with food products.
Do not use the machine outdoors.
Do not use the machine in a wet environment.
Do not use the machine in an environment in which particulate matter is present.
Machinery Directive 2006/42/EC
It is a violation of Machinery Directive 2006/42/EC to operate this equipment in an EU member
state if the user manual is not written in that state’s language. Contact Weber Marking Systems
GmbH for translated user manuals
Safety Guarding
If the Model 4300 printer-applicator is intended for integration into other machinery to be operated
in the European Union, it is the responsibility of the equipment integrator, installer, and end user to
ensure that the equipment is properly guarded in accordance with standard EN294:1992. Please
refer to EN294 for exact specifications.
Stop Function
A Stop feature is included for use with standalone applicators or with applicators incorporated with
the other machines that perform the product handling functions. For all applications, the Stop
function is as follows:
When activated, the Stop function positions the tamp in the up or retracted
position. This is to provide the minimum hazard exposure in accordance with
the risk analysis for the operator or property.
The optional customer-provided Stop switch can be installed and mounted for
appropriate access by the operator.

General Information
Weber Packaging Solutions, Inc. 2-3
The Stop feature can be wired in series with other equipment stop facilities,
upstream or downstream of the applicator, and ganged with the system E-Stop.
As stated by EN418, no emergency switch device will be provided as standard
equipment.
See Chapter 9, Appendix for information on installing the optional Stop switch.
! NOTICE ! MINIMUM CREEPAGE DISTANCES AND DOUBLE INSULATION
SPECIFIED IN EN60204 MUST BE PROVIDED WHEN USING
CUSTOMER-SUPPLIED EMERGENCY STOP DEVICE.
! ADVERTISSEMENT ! LA DISTANCE DU RAMPAGE [CREEPAGE] MINIMUME ET LE
DOUBLE-ISOLEMENT QUI EST SpÉCIFIé SELON LA NORME
EN60204 DOIVENT ÊTRE FOURNES LORSQUE LE CLIENT
FOURNIT APPAREIL D’INTERRUPTION D’URGENCE.
! ACHTUNG ! MINIMALE KRIECHSTRECKE UND DOPPELTE ISOLIERUNG
SPEZIFIZIERTE IN EN 60204 MUSS VERFÜGT WERDEN WENN
VERWENDEN DEN KUNDENLIEFERTEN NOTSCHALTER.
Pneumatic Power Supply Failure
It is the responsibility of the equipment installer, integrator, and end user to supply a safety pressure
switch. The safety pressure switch must disengage the pneumatic power supply to the applicator when
pneumatic power is lost, the stop button is pressed, or a door switch tripped. (See Figure 2-1.)

Chapter 2
2-4 Printer-Applicator User’s Manual
Figure 2-1: Safety Pressure Switch

General Information
Weber Packaging Solutions, Inc. 2-5
Machine Layout and Components
RIGHT-HAND LEFT-HAND
CONTROLLER CONTROLLER
UNWIND
UNWIND
DISK
DANCER
ARM
REWIND
MANDREL
DANCER
ARM IDLER
ROLLER PRINTER PELLER
BAR AIR ASSIST
TUBE
TAMP PAD &
MANIFOLD
TAMP
ASSEMBLY
UNWIND
UNWIND
DISK
DANCER
ARM
REWIND
MANDREL
DANCER
ARM
IDLER
ROLLER
PRINTER
PELLER
BAR
AIR ASSIST
TUBE
TAMP PAD &
MANIFOLD
TAMP
ASSEMBLY
Figure 2-2: Model 4300 Printer-Applicator Front View
CONTROL
ENCLOSURE
AIR
GAUGES
REGULATORS
Figure 2-3: Model 4300 Printer-Applicator Top View

Chapter 2
2-6 Printer-Applicator User’s Manual
POWER OUTPUT
FOR PRINT ENGINE
POWER
INPUT MODULE
MAIN POWER SWITCH
INPUT/OUTPUT
CONNECTOR
STROBE
RECEPTACLE PRODUCT
DETECTOR
RECEPTACLE
AIR ASSIST TUBE
TAMP PAD
PRODUCT
DETECTOR
RECEPTACLE
LABEL
UNWIND
DISKS
LOW LABEL
DETECTOR
TAMP ASSEMBLY
ADJUSTMENT LEVERS
ZERO DOWNTIME
RECEPTACLE
Figure 2-4: Model 4300 Printer-Applicator Side View and Back View