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

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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
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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

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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
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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
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