model 5200 printer-applicator - weber packaging

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: 847-364-8500 Fax: 847-364-8575

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 Warning 9-10 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

iv Printer-Applicator User’s Manual

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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


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 more information. 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 M ODEL 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


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


Customer Support

Technical support representatives are available 7:00 AM to 5:00 PM CT Monday through Friday.

Call 1.800.323.9519


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

Chapter 2


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


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


Figure 2-1: Safety Pressure Switch

General Information


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

ROLLERPRINTERPELLER

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


POWER OUTPUT

FOR PRINT ENGINE

POWER

INPUT MODULE

MAIN POWER SWITCH

INPUT/OUTPUT

CONNECTOR

STROBE

RECEPTACLEPRODUCT

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


Overview

3 Preliminary Setup

This chapter includes procedures for the preliminary setup of the

Model 4300 printer-applicator that needs to be completed before the

AC power and compressed air are connected to the machine.

The preliminary setup procedures include:

Printer-applicator unpacking, T-base mounting, moving, and transporting

Tamp pad setup

Tamp pad removal

Chassis cover installation/removal

Printer cable installation

Ribbon label loading

Label width setting

Air filter setup

! CAUTION ! Do not connect the machine to the AC power source or to the

compressed air service until directed to do so in the set-up procedures (see Chapter 4).

Chapter 3


Printer-Applicator Unpacking, T-Base Mounting, Moving, and Transporting

Note: In most cases, the print engine has been mounted onto the applicator chassis at the factory.

See the print engine manual for mounting information.

Unpacking and T-Base Mounting the Printer-Applicator

To unpack and position the printer-applicator:

1. Cut the corners of the inner carton with a box cutter and fold the sides down.

2. Remove U-arm from packaging & install onto the applicator.

3. Remove the printer-applicator from the packaging.

4. Make sure the fasteners connecting the printer-applicator to the U-arm are securely

tightened.

5. Lift the printer-applicator from the carton by grasping the U-arm at positions A and B .

! CAUTION ! The machine weighs up to 180 lbs (82 kg) and should be

handled by two people.

Figure 3-1: U-Arm Mounting - Right Hand

POSITION "A"

POSITION "A"

POSITION "B" POSITION "B"

(3) ½” Flat Washers

(3) ½” Lock Washers

(3) ½” – 13 x 1 ¾” Cap screws

Note: Tighten the 3 cap screws to 41 ft/lbs + 2 ft/lbs

Preliminary Setup


6. Place the printer-applicator on a stable work surface approximately 32" high and with

clearance underneath for the front leg of the T-base.

7. Assemble the Weber T-base according to the assembly instructions included with the

T-base.

8. Mate the printer-applicator with the Weber T-base. Do this by adjusting the height of

the carriage until the U-arm mounting bolt can pass through the mounting hole in the

U-arm.

9. Assemble the lock washer and nut on the mounting bolt of the carriage and tighten

securely. Raise the carriage to lift the applicator off the work surface.

! CAUTION ! Take care when tightening the U-arm bolts or moving the printer-

applicator to avoid tipping. Adjust the carriage to its lowest position when servicing the applicator. Do not use the T-base to ship the applicator.

10. Adjust the carriage height as required for the application.

Note: To achieve the desired machine attitude, rotate the applicator only about one axis at a

time. Either rotate the applicator about the U-arm or rotate the U-arm about the T-base

carriage. Do not attempt to rotate both simultaneously.

Chapter 3


Moving and Transporting the Printer-Applicator

The T-base is designed only to provide roll-away access from the adjacent labeling area for

applicator service. Take care when moving the machine to prevent tipping.

! CAUTION ! Cracks and bumps in the floor may cause a caster to suddenly

stop or change direction.

To move the printer-applicator:

1. Return the applicator to an “upright and above” orientation on the T-base stand. Rotate

the printer-applicator about one axis at a time to achieve this.

2. Lower the applicator to the bottom of travel on the T-base vertical carriage.

To transport the printer-applicator:

If the applicator needs to be transported over a greater distance, additional safety measures must

be followed.

1. Remove the printer-applicator from the T-base.

2. Properly repack the equipment for shipping.

Preliminary Setup


Ribbon and Label Loading

Refer to your specific Print Engine Manual for more information on loading the printer ribbon and the

label stock or printing media.

Ribbon Loading

1. Set the print engine [POWER ON/OFF] switch to the OFF position.

2. Open the printer cover.

3. Refer to your specific Print Engine Manual for the ribbon loading procedure.

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

ROLLERPRINTERPELLER

BAR

AIR ASSIST

TUBE

TAMP PAD &

MANIFOLD

TAMP

ASSEMBLY

Figure 3-2: Removing/Loading Labels

Chapter 3


Label Loading

1. Set the main [POWER ON/OFF] switch to the OFF position.

2. Rotate the outer unwind disk to align the set screw with the flat on the unwind mandrel,

(see Figure 3-2). Remove the outer unwind disk from the unwind mandrel.

3. Load the label roll onto the hub of the inner unwind disk and up against the inner

unwind disk. The label roll must be oriented so that the material passes through the print

head with the label side up. Install the outer disk up against the label roll and rotate to

secure it onto the unwind mandrel.

4. Peel off the first three feet of labels from the label liner.

5. Refer to your specific Print Engine Manual for more information on loading the label

stock or print media into the printer.

6. Thread the label stock (see Figure 3-3).

7. Remove the pin from the rewind mandrel.

8. Place the label liner over the rewind pin groove and then reinstall the pin so it captures

the liner in the groove.

9. Make sure that the inner edge of the label liner moves in a straight line from the inner

unwind disk through the printer.

10. Turn the rewind mandrel until all the slack is removed between the peeler bar and the

rewind mandrel (have 2-3 wraps to start).

Figure 3-3: Label Routing Diagram

Label Width Setting

The print engine should have a label width, print width, head level adjustment, or a head

pressure adjustment. This setting must be adjusted according to the width of the label.

Refer to your specific Print Engine Manual for information on this adjustment.

Preliminary Setup


Tamp Pad Setup

Overview

All applicators with tamp units are supplied with standard tamp pads that are available in a

range of sizes and feature a predrilled hole design. This design allows them to be configured for

use with a great variety of labels starting with length and widths of one inch or more. Before

using, the tamp pad holes need to be "punched out" in a pattern to match the label size and

allow for proper application.

General Information

Use the following instructions as guidelines for establishing the hole pattern needed for a

variety of common label applications. The actual patterns shown may be reduced or enlarged to

work for your label size. The number of holes also may have to be reduced or increased to

maintain the pattern symmetry and proportion. If a mistake is made, the punched hole can

simply be covered with a piece of cellophane tape. (The tape should be put on the side of the

pad that mates with the manifold.)

Never punch out all the vacuum/blow holes! This would result in poor label feed and weak

label blow off. The type of application and the label size dictate the hole pattern required.

Punching Instructions and Safety

! CAUTION ! Disconnect the power from the AC power source.

Remove the tamp pad from the manifold.

Start by placing the tamp pad (hole side up) on corrugated cardboard that is

resting on a hard supporting surface.

Insert the "pin punch" supplied with the applicator into the selected predrilled

hole.

While wearing protective gloves and safety glasses, use a brass hammer (do

not use a hammer with a hardened head) to strike the punch and complete the

hole through the tamp pad. Repeat for all the holes in your pattern. Do not

turn the punch over as the end struck by the hammer will mushroom from

being struck by the hammer and get stuck!

Make sure that all slugs produced from knocking out the blind hole are fully

removed from the tamp pad BEFORE re-installing the tamp pad on the

manifold.

When the desired hole pattern is achieved, mount the tamp pad to the

manifold.

Note: Any slug that is not fully detached from the pad prior to reinstalling the tamp

pad to the manifold will become lodged in the pneumatic tubing or pneumatic values,

thus reducing available vacuum. Therefore, do not knock out any slugs with the tamp

pad still mounted to the manifold.

Chapter 3


Tamp Blow Configuration

Tamp blow applicators use the tamp pad holes to receive a label and transfer it to a product with

a blast of air. This is accomplished with a pattern that is symmetrical about the center of the

short axis of the label.

The holes are concentrated across the middle of the short side of the label. The spacing

gradually increases along the long side, away from the centerline. Spacing across the short

width of the label must be fairly even. The purpose of this pattern is to slightly bend the label as

it is being applied and eliminate trapping air. Punching too many holes will reduce performance.

TAMP PADLABEL FEED

AIR BLAST

LABEL

APPLICATION SURFACE

Figure 3-4: Tamp Blow Label Application

Preliminary Setup


LABEL FEED= PUNCHED HOLE

Figure 3-5: Tamp Blow Hole Pattern for a 4” x 6” Label

Chapter 3


Tamp Blow Flag Configuration

The vacuum/blow-off holes are configured basically the same as a standard tamp blow pad. The

only difference is the portion of the label intended to be flagged off of the side of the product.

The objective is to hold the label as it is dispensed from the printer, then transfer it to the

product with a blast of air without having the flagged portion blown around the corner.

This configuration is accomplished by reducing the number of vacuum/blow holes in the area of

the flagged portion of the label. In this case the holes are still concentrated across the middle of

the label. The spacing gradually increases along the long side, away from the centerline.

Spacing across the short side of the label must be fairly even with fewer holes in the flagged

area.

LABEL FEED= PUNCHED HOLE

FLAGGED AREA OF LABEL

Figure 3-6: Tamp Blow Hole Pattern for a Flagged 4” x 6” Label

Preliminary Setup


Air Filter Setup

NOTE: The air filter assembly must be connected to the applicator prior to operation.

Failure to do so will result in a decrease in performance and/or applicator failure.

The air filter removes particulate material from the plant air supply. The filter assembly consists on the

fitting, filter, and mounting bracket.

To install the air filter:

1. Attach the mounting bracket on the side of the applicator U-arm with 2 cap screws.

NOTE: The bracket must be oriented so the filter will be perpendicular from the

floor for proper operation.

2. Attach the filter to the mounting bracket with 2 long cap screws.

3. Connect the air hose from the applicator to the outlet side of the filter.

AIR

FILTER

INDUSTRIAL

INTERCHANGE FITTING

(MALE)

Figure 3-7: Air Filter

Chapter 3




Overview

4 Applicator Setup

This chapter covers the setup procedures for the label applicator. These

procedures include label and tamp adjustments and air pressure settings.

This chapter also includes operational tests and alarm conditions. Some

of these procedures require the machine to be powered and the air

pressure applied.

Connection to AC Power

To turn on the AC power:

NOTE: The applicator should be plugged into a branch circuit rated at 115/230 VAC,

50/60 Hz, 15/20 A. The applicator is fuse protected. If the voltage is substantially lower

than 115/230 VAC, the applicator may function improperly.

1. Set the main [POWER ON/OFF] switch to the [OFF] position.

2. Connect the end of an unplugged AC power cord to the IEC receptacle on the rear of the

applicator.

3. Plug the other end of the AC power cord into an electrical outlet (115VAC).

4. Before turning on the applicator power, be prepared to catch labels that may be

dispensed by the printer when it starts up. Set the main [POWER ON/OFF] switch to

the ON position.

Chapter 4


Compressed Air

Compressed Air Connection

To supply compressed air:

1. Make sure the air filter setup is complete (see Chapter 3, Preliminary Setup).

2. Use the supplied pneumatic hose to connect to the plant air supply. The fitting on the

filter assembly uses a 3/8” industrial interchange connector.

3. Make sure the tamp air regulator is set to 30 psig. when the air pressure is on, the tamp

should move to the retract position.

Air Assist Adjustment

To adjust the air assist:

1. Open the air assist regulator half-way.

2. Loosen the screws in the air assist tube bracket slotted holes and reposition the air assist

tube so it does not stick out past the peeler bar by loosening the screws in the bracket

slotted holes and repositioning. The tamp pad must not contact the air assist tube when

it extends and retracts.

3. Check to see that the air hole in the air assist tube is pointing towards the front edge of

the tamp pad and is centered across the width of the label. The air assist tube is secured

by a socket head cap screw. Loosen the cap screw and re-adjust the air assist tube if

necessary (see Figure 4-1).

NOTE: The following adjustments require the print engine to be properly set up

to feed a label in order to proceed. Check the label stop position. The print engine

must fully feed a label so it is completely released from the backing sheet and onto

the tamp pad.

Applicator Setup


4. Set the main [POWER ON/OFF] switch to the ON position. Wait for the applicator and

print engine to fully power up.

5. Press the [FEED] button on the print engine to dispense a label.

6. If the label is not fully dispensed from the label liner a the end of the feed, the stop

position must be adjusted. If the label is fully dispensed and the next label also begins to

dispense (extends past the peeler bar) at the end of the feed, the stop position must be

adjusted.

7. Refer to the Print Engine Manual for specific instructions on how to adjust the stop

position of the label.

Figure 4-1: Air Assist Tube Alignment

Tamp Home Adjustment

The tamp home position is where the tamp pad receives the label after it has been printed. The tamp

will then extend to apply the label to the product. For most situations, the tamp home adjustment

should be set to a position where the pad surface is one label thickness above the printer peeler bar.

PAD SURFACE

LABEL

RIGHT HAND

Figure 4-2: Printer Peeler Bar/Tamp Home Alignment

Chapter 4


If the tamp pad is adjusted too low, the label will feed into the back of the pad and jam. If the tamp

pad is adjusted too high, the label will not feed correctly onto the pad.

This adjustment may need to be changed when different label materials are used.

RIGHT-HAND

MOUNTING

SCREWS

Figure 4-3: Tamp Home Adjustment

To adjust the tamp home position:

1. Back the tamp-regulator completely down to 0 PSIG.

2. Before the tamp height is adjusted, be aware of the tamp home sensor. It is used to sense

when the piston is in its home or extended position. It should always be checked and

adjusted whenever the tamp home position is changed.

Flow Control

Tamp Home Sensor

Cylinder Rod

Jam Nut Floating Coupler

Applicator Setup


3. The tamp home position is adjusted by loosening the jam nut that locks the cylinder rod

to the floating coupling. Thread the cylinder rod into the coupling to raise the pad. Back

the rod out to lower the pad (see Figure 4-3).

4. Readjust and secure the Tamp Home sensor. See the Tamp Home Sensor Adjustment

Procedure in Chapter 7, Maintenance.

5. Slowly open the tamp-regulator back up to 30 psig (2 bar).

6. Set the main [POWER ON/OFF] switch to ON.

7. Use the [JOG] button to cycle the machine. Check the pad height setting and tamp home

sensor. Re-adjust as needed.

Tamp Pad/Label Alignment

There are two adjustments that can be made to align the tamp pad with the label:

The inboard edge of the tamp pad must be aligned with the inboard edge of the label.

The upstream edge of the tamp pad must be close enough to the printer peeler bar in

order to properly receive the label.

Figure 4-4: Inboard Edge of the Tamp Pad Aligned with Inboard Edge of Label

Tamp Assembly Stop

Chapter 4


Figure 4-5: Upstream Edge of Tamp Pad Close to Printer Peeler Bar

Figure 4-6: Tamp Pad Label Alignment

Manifold Knobs (4)

Tamp Assembly Lever Handles

Applicator Setup


To align the tamp pad/label:

1. Set the main [POWER ON/OFF] switch to the OFF position.

2. Back the tamp-regulator completely down to 0 PSIG.

3. Loosen the tamp assembly stop and leave free for now (See Figure 4-4).

4. Align the inboard edge of the tamp pad with the inboard edge of the label. This is done

by loosening the manifolds knobs and sliding the tamp pad towards or away from the

faceplate. Tighten the knobs after aligning. (See Figure 4-5.)

5. Align the upstream edge of the tamp pad with the upstream edge of the label by

loosening the two lever handles on the back of the tamp assembly. Make sure the tamp

pad clears the peeler bar and air assist tube when it moves from home to extended

position. There should be a 1/32 to 1/16 inch gap between the tamp pad and peeler bar.

Tighten the lever handles. (See Figure 4-6.)

6. Slowly turn the tamp-regulator back up to 30 psig (2 bar).



8. Press the [JOG] button to cycle the machine.

9. Re-check the tamp pad/label alignment and repeat this procedure if necessary.

Vacuum and Air Assist Regulator Adjustment

To adjust the vacuum and air assist regulator:

1. Turn the vacuum regulator fully closed so vacuum is completely off (see Figure 4-7).

2. Press the [FEED] button to dispense a label. Hold it against the tamp pad with your

finger.

3. Slowly open the vacuum regulator to increase the vacuum until you can feel it holding

the label as you pull your finger away.

4. Press the [FEED] button to dispense another label. If the tamp vacuum doesn’t catch the

label, observe the label as it begins to feed. The air assist must help push the label

towards the tamp pad so the vacuum can catch the label. Increase the air assist regulator

as needed. If the air assist is good, observe the vacuum to make sure the label is caught

by the tamp pad.

If it is not caught, increase the vacuum regulator and re-try.

If it “hops” when feeding, decrease the vacuum regulator and re-try.

Chapter 4


Figure 4-7: Regulators

Tamp Regulator

Air Assist Regulator

Vacuum Regulator

Tamp Regulator

Applicator Setup


Tamp Adjustment

The tamp pressure, flow controls, and cylinder cushions are factory pre-set. Use the following

instructions to check the tamp function and to make adjustments only if necessary.

To adjust the tamp:

1. Check/adjust the filter-regulator to be sure it is set to 30 PSIG (2 bar).



3. Press the [JOG] button to cycle several labels through the applicator to observe the tamp

action. It should move quickly & smoothly without slamming to a sudden stop at either

end of its stroke.

4. If the tamp does not move quickly and smoothly, or if it slams to a stop at either end of

its stroke, locate the two flow controls on the tamp assembly.

NOTE: These flow controls are meter-out function (see Figure 4-8).

5. Press the [JOG] button to dispense a label onto the tamp pad and trip the product

detector to cycle a label through the applicator. Adjust the air control valves until the

tamp extends and retracts quickly as the machine cycles, but does not slam to a stop at

either end.

6. See section regarding Measure Cycle Time. Required times are for the following

Stroke Length Extend Time Minimum Retract Time Minimum

2” (50mm) 125ms 125ms

3” (80mm) 200ms 200 ms

6” (160mm) 400ms 400ms

8” (200mm) 500ms 500 ms

10” (250mm) 625ms 625ms

12” (300mm) 750ms 750ms

NOTE: Do not go lower than the time values in the chart or the tamp assembly may

be damaged and the product life reduced.

7. Tighten the lock nuts on both flow controls.

Chapter 4


RIGHT-HAND

MOUNTING

SCREWS

Figure 4-8: Tamp Adjustment

Retract Flow Control

Retract Cushion

Tamp Home Sensor

Extend Cushion

Extend Flow Control

Applicator Setup


Air Blast Adjustment

The Air Blast Regulator is factory-set to give the best label application performance for a wide variety

of label sizes. Adjustments may be made to the air blast timer and air blast regulator.

Refer to Chapter 6 to see how to access and set the air blast time menu on the controller.

To adjust the air blast:

1. Position the applicator to apply a label to a product. The tamp, when fully extended,

should stop ¼” away from the product to be labeled.



3. Place a stationary product below the tamp and press the [FEED] button to dispense a

label on the tamp pad, then trip the product detector to cycle the tamp and transfer the

label to the product.

4. Observe the transfer of the label. Make sure the air blast duration is long enough to

allow the air jets to transfer the label.

5. Some experimentation will be necessary to find the best time to use.

Chapter 4


Static Stack Test

Figure 4-9: Static Stack Adjustment Flow Chart

The static stack test is used to test the applicator setup. This test applies several labels to one stationary

product. If these labels are applied directly on top of each other and aligned neatly with each other,

then the applicator has been setup correctly for that label.

Applicator Setup


To perform a static stack test:

1. Place a product under the tamp.

2. Load the label information into the printer’s buffer.

3. Make sure that the main [POWER ON/OFF] switch is in the ON position.

4. Press the [FEED] button to dispense a label on the tamp pad, then trip the product

detector to apply the label to the product. Repeat several times.

If the labels are neatly stacked one on top of the other, you have correctly

setup the applicator.

If the variation isn’t within the required tolerances, follow the instructions

below to help you find and correct the problem.

5. Check the label position on the tamp pad.

Each label must be applied exactly from the same position on the pad. The inboard edge

of the label should be aligned with the inboard edge of the tamp pad, or, centered across

the hole pattern of the width of the label.

NOTE: If the tamp pad and label do not line up, perform the tamp pad/label

alignment procedure and then return to step 1.

6. Check the label stop position.

Check the stop position of the label on the peeler bar. When one label is

completely dispensed, the leading edge of the next label should be 1/16” or

back from the edge of the peeler bar.

Press the [FEED] button to dispense a label on the tamp pad, then trip the

product detector to apply the label to the product. Repeat several times.

If the labels are all placed within 1/16” of each other, the position is set

correctly.

If not, adjust the Offset printer variable (see the Print Engine Manual).

7. Check the surface of the tamp pad.

The surface of the tamp pad should be clean and free of any label adhesive. If the pad

requires cleaning, wipe the surface with alcohol.

8. Check the vacuum

Press the [FEED] button to dispense a label. Check to see if the label buckles

when it slides onto the pad. If it does, then the vacuum is too strong and it

will need to be reduced.

Press the [FEED] key to dispense a label. If the label falls off or slides forward

after leaving the peeler bar, then the vacuum isn’t strong enough and it will

need to be increased.

Chapter 4


9. Check the Air Assist

The air assist tube should be parallel to the tip of the peeler bar. The air

hole(s) should be centered (or evenly spaced) on the label across the feed

direction of the web, and pointing towards the front edge of the tamp pad.

Press the [FEED] button to advance a label. If the label is moving on the pad

after it has been completely dispensed, decrease the air assist pressure. If the

initial edge of the label is not pushed against the tamp pad, increase the air

assist flow control.

10. Check for Adhesive Strings

Open the print head and disengage the drive and nip rollers. Turn the rewind

mandrel by hand to dispense a label.

If the label follows the liner around the peeler bar and doesn’t dispense easily,

the label is being held to the liner by “adhesive strings”.

The air assist tube can sometimes be useful in getting labels with adhesive

strings to properly dispense. Try increasing the air assist flow control to help.

If the label still feeds onto the pad incorrectly, replace the label roll and try

again.

11. Check to see that the tamp pad is the proper distance from the product to transfer the

label.

Tamp pad should be about ¼ inch away from the product.

Applicator Setup


Low Label Sensor Adjustment

The low label sensor is a photoelectric sensor that is used to trigger an alarm when the label supply is

low. This section contains procedures for:

Checking the sensor functionality

Adjusting the sensor sensitivity

Adjusting the sensor trigger point

Low Label Sensor Functionality

! CAUTION ! Use caution when cycling the machine. Keep hands away from

the tamp.

To check the low label sensor functionality:

1. Push the unwind roll dancer arm toward the printer to release the break band.

2. Rotate the unwind roll until the opening in the inner unwind disk is right in front of the

low label sensor.

3. Remove the outer unwind disk and remove the label roll from the unwind mandrel.

4. If the low label sensor sensitivity is properly set, the alarm light will begin to flash

slowly.

5. If the alarm light is not flashing, adjust the sensor sensitivity.

LOW LABEL

SENSOR

Figure 4-10: Low Label Sensor

Chapter 4


Low Label Sensitivity Adjustment

Note: There are two sensor styles—Banner and Optex. Indentify the style before

making any sensitivity adjustments.

Optex

Figure 4-11: Low Label Sensor Styles

Banner Style

When the low label sensor sensitivity is set correctly:

The red LED on the back of the sensor will turn [ON] when the sensor is blocked by the

label roll or by the unwind disk.

The red LED on the back of the sensor will turn [OFF] when it is not blocked by the


Optex Style

When the low label sensor sensitivity is set correctly:

The green LED on the top of the sensor will turn [ON] when power is applied to the

sensor.

The yellow LED on the top of the sensor will turn [OFF] when it is not blocked by the



the tamp.

Applicator Setup


To adjust the low label sensitivity:

1. Push the unwind roll dancer arm toward the printer.

2. Rotate the unwind roll until the opening in the inner unwind disk is right in front of the

low label sensor.

3. Remove the back cover from the low label sensor (Banner sensor only).

4. Set the output select switch to the Dark Operate (DO) position (Banner sensor only).

Banner sensor: Turn the adjustment screw until a red spot is focused sharply

on the label roll.

Optex sensor: Turn the adjustment dial until the yellow LED stays on.

5. Rotate the unwind disk until the red spot is directed away from the opening and onto the

disk itself. The red LED (Banner sensor) or yellow LED (Optex sensor) should stay

[ON].

Note: Adjust the sensitivity (if necessary) until the LED remains on when the

unwind disk or the label roll is in front of the sensor.

6. Rotate the unwind disk until the red spot is directed through the opening onto the label

roll.

7. Take the outer unwind disk off and remove the label roll from the unwind mandrel. The

LED should then go OFF.

Chapter 4


Low Label Sensor Trigger Point

The low label sensor trigger point is the level of label supply that will activate the sensor light.


the tamp.

To adjust the sensor trigger point:

1. Move the unwind roller dancer arm toward the printer.

2. Rotate the unwind roller until the opening in the inner unwind disk is in front of the low

label sensor. Make note of the red spot on the label supply. The spot is the trigger point

where the sensor will turn off when the supply roll is depleted below the spot.

3. Loosen the low label sensor’s front mounting nut and slide the sensor horizontally on

the bracket to the desired trigger point. (see).

4. Tighten the front mounting nut.

LOW LABEL

SENSOR

Figure 4-12: Low Label Sensor Trigger Point

Applicator Setup


Machine Attitudes

RIGHT-HAND

NOSE DOWN NOSE

UPRIGHT AND ABOVE BOTTOM UP

REELS UP

INDICATES LABLE FEED

DIRECTION

Chapter 4


LEFT-HAND

NOSE DOWNNOSE

UPRIGHT AND ABOVE BOTTOM UP

REELS UP

INDICATES LABLE FEED

DIRECTION

Applicator Setup


Rotatable Display

The Model 4300 controller display can be rotated to provide the best operator access given a particular

machine orientation.

To rotate the display:

1. Turn off power and remove AC power cord from the line supply.

2. Remove the four screws holding the display to the Model 400 faceplate.

3. Carefully pull the display and plate forward enough for the circuit boards to clear the

face plate.

4. Rotate the display to the desired position.

5. Carefully push the display, plate, and cables back towards the faceplate until plate is

flush with the faceplate.

6. Re-install the four plate mounting screws.

Figure 4-13: Normal Display Orientation

Figure 4-14: Display Rotated 90° for “Nose Up” Attitude

mounting

screws for

display (4)

mounting

screws for

display (4)

Chapter 4




5 Product Detector Setup

This chapter covers the setup and adjustment procedures for the product

detector. It explains how to position the applicator and adjust its

sensitivity.

Positioning the Applicator

The applicator needs to be in a position to properly apply a label to the product. Make sure that all the

moving parts have enough clearance to avoid any obstacles in the area.

The product must be repeatedly fed into the applicator in order to attain label placement accuracy.

Product Detector Sensitivity Setup

Mount the product detector and its reflector (if applicable) before adjusting the product detector

sensitivity. The detector may need to be repositioned when actual products are being labeled. Refer to

the instructions included in the product detector packaging.

Overview

Chapter 5


Product Detector Position

Mount the product detector and its reflector (if applicable) before adjusting the product detector

sensitivity. The detector may need to be repositioned when actual products are being labeled.

1. Position a product in front of the tamp so that the product will be labeled in the correct

position.

2. Position the product detector so that it is even with (or slightly upstream from) the

leading edge of the product (or trailing edge if you set the active product edge detection

to trailing).

3. Set the conveyor to the production speed.

4. With a label waiting on the tamp pad, send a product down the conveyor and watch as it

is applied. If the label is applied too soon or too late, reposition the product detector.

Continue to make adjustments until the label is applied in the correct location.

NOTE: The tamp extend may also be used to delay when the label is applied to the

product. Using long delay times will decrease the applicator throughput capability.

Test Run

After you have completed the Product Detector Setup, send some label jobs to the printer and

load several products on a conveyor. Check the position of the labels and make sure that they

are consistently positioned on each product. If not, make sure that the conveyor is consistently

transporting products past the applicator. Review the applicator setup procedures to make sure

that you have completed all the instructions correctly. See Applicator Setup, Chapter 4.

NOTE: Be sure to record your settings for future reference.


Overview

6 Controller Operation

This chapter describes all the functions in the controller, how to use

them to adjust the applicator, along with the menu. This chapter also

includes error codes for assistance in troubleshooting the machine. This

chapter starts with flow charts showing how to use the controller

keypad to navigate through the menus in the controller.

For more operational information, refer to Applicator Setup, Chapter 4.

Applicator Menu Flowchart

The following flowchart maps the navigation through the controller. When the applicator is turned on,

the splash screen scrolls across the display showing the current applicator software version and then

the Idle Mode screen appears. Using the arrow keys on the controller keypad (see Figure 6-2), the

operator can scroll through the various menu screens. Refer to the sections immediately following the

flowchart for detailed information about main screen settings and applications.

Chapter 6


Figure 6-1: Controller Menus Flowchart

Controller Operation


IDLE MODE

TAMP BLOW

DISPLAY

WINDOW

N/A

READY (GREEN)

PRINTER ENABLE

(GREEN)

N/A

LOW SUPPLY

(YELLOW)

RETURN BUTTON / STOPINCREASE / DECREASE

BUTTONS

ARROW BUTTONS

L.E.D.s

IDLE MODE

(RED)

APPLICATOR MODE

JOG

Figure 6-2: Controller Keypad

Controller Keypad

The applicator controller is located on front of the applicator (see Figure 6-2).

NOTE: The top line in the display window indicates the current mode of the applicator.

NOTE: In order for the machine to run, air must also be supplied to the machine.

The arrows in the display window indicate which arrow buttons to use to scroll through

the menus and to select the desired function. For example, in Fig 6.2, the applicator is in

Idle mode and to select Tamp Blow a user would press the [] down arrow key as

indicated by the arrow symbol extending from the Idle mode box.

The [+] and [-] buttons are used to increase or decrease numerical parameters.

The [RETURN] button returns the operator to the previous menu. Also, pressing this

button while the applicator is running will stop the cycle and allow access to the

Diagnostics or Setup screen.

The active selection is highlighted in the display window.

The LEDs light to display applicator status as follows:

RED – Error (applicator is in Idle or Error mode)

GREEN – Ready (applicator in Run mode) or Print Enable (Print start)

YELLOW – Warning (Low supply condition)

Tap the [JOG] to apply a previously printed label when the machine is in Run Mode.

Chapter 6


Setup Menu

The Setup Menu allows the operator to set the parameters for the following applicator functions:

Set Options, Active Edge Mode, Set Run Mode and Set Timers. See the following sections for

menu and function information.

Set Options

Trigger Count

The number of product detector events that must occur per label application event.

The factory default value is 1.

LOP Sensor

LOP (label-on-pad) is an optional sensor that is available to detect the presence of a

label on the tamp pad. If enabled, the controller checks for a label on the pad after a

print cycle and issues a general error if the label is not present.

The factory default value is OFF.

Tamp Error

When enabled, the applicator issues an error when the tamp assembly moved off the

home position without instruction from the control system.


Factory Setup

Returns all parameters to the factory set defaults.

Run At Start Mode

When enabled the machine enters RUN mode after the power is applied. When disabled

the machine enters IDLE mode after the power is applied.

The factory default value is ON.

Vacuum Shut-Off

The Vacuum Shut-off feature turns off vacuum when it is not needed to conserve

compressed air resources. Vacuum is applied automatically at the start of label printing.

This is an optional feature that requires an additional pneumatic solenoid valve.


VT Air Blast Only

When enabled and an optional Variable Tamp (VT) Sensor is installed, tripping the VT

Sensor issues an Air Blast event but does not retract the tamp. The tamp continues to

extend until the TAMP Extend time expires.




Active Edge

Active Edge specifies the edge of the product that is to be used to start the label application

process.

LEADING – detects the front edge of the product

TRAILING – detects the rear edge of the product

CONTINUOUS – does not wait for the product, but applies the label when the label is finished

printing.

The factory default setting is LEADING

Set Language

Use the arrow buttons to select the desired language.

English

Francois (French)

Deutsch (German)

Espanol (Spanish)

Set Timers

Air Blast

The air blast setting controls the duration of the air blast that applies the label to the

product. Various factors, such as distance of tamp pad to the product or size of the label

affect the air blast time. For optimum machine cycle time, the blast time should be just

slightly longer than the time required to apply the label firmly.

The factory default value is 125. Range is 25 to 500 milliseconds adjustable in

increments of 25 milliseconds.

Tamp Extend

The Tamp Extend setting controls the time the tamp is extended before blowing the

label onto the product. The tamp retracts once the tamp extend time is satisfied.

The factory default value is 500. Range is 0 to 500 milliseconds adjustable in

increments of 250 milliseconds.

NOTE: If the tamp extend time is set too short, the full stroke of the tamp may not be

achieved. If the tamp extend time is set too long, the label may not be applied at the

correct time or to the correct product.

NOTE: For machines equipped with the Variable Stroke Sensor Option, set the tamp

extend time to a maximum of 500ms so the timer does not interfere with the sensor.

In addition, this will prevent the tamp from staying in the extended state if a product is

not detected by the sensor.

Chapter 6


Tamp Fault

Tamp fault is an error detection feature to catch when the tamp is obstructed and cannot

move. When a label-apply cycle is initiated, the controller monitors the tamp-home

sensor and waits for the sensor to indicate that the tamp has begun to extend. If the tamp

does not begin to extend within the specified time, the label-apply cycle terminates.

The tamp fault timeout value sets the amount of time the machine waits before testing

whether the tamp has left the home position.

The factory default value is 0. Range is 0 to 500 milliseconds adjustable in increments

of 25 milliseconds. Setting the value to 0 disables this feature.

LOP Settle Time

LOP settle time is an adjustable delay to allow the label to “settle” on the pad before its

presence is checked by the control system. Increasing the value allows the controller

more time to accurately determine if the label was transferred to the pad. If adequate

time is not allowed then false LOP errors may be generated.

The factory default value is 0. Range is 0 to 9999ms.

Product Delay

Sets amount of time the applicator waits to apply a label after the product sensor is

tripped. Product Delay is useful when a product detector cannot be positioned in the

correct location or when the label position must be changed without changing the

product detector position. The delay is equivalent to physically moving the sensor to

another location.

The factory default value is 0. Range is 0 to 9999ms.

Start-up Delay

Sets amount of time the applicator waits for the printer to power up to a state where

label printing can begin. During the Startup Delay, the controller ignores all printer

interface signals. Some printers can take up to 30 seconds to power-up.

The factory default value is 15. Range is 0 to 99 seconds.



Set Run Mode

The following table summarizes the trigger options available with each application mode.

Mode Product Detector IN01

Trigger Apply IN01

Trigger Print IN12

Notes

Tamp Blow Apply Label Apply Label

Tamp Blow PA Print and Apply Label

Print and Apply Label

One sensor or signal prints and applies a label.

Tamp Blow PA Apply Label Apply Label Print Label Separate signals to print and apply a label.

Air Blow Apply Label Apply Label

Air Blow PA Print and Apply Label



Air Blow PA Apply Label Apply Label Print Label Separate signals to print and apply a label.

Inverted Tamp Blow

Apply Label Apply Label

Chapter 6


Diagnostics Screen

The Diagnostics Screen allows the operator to run a test cycle, view inputs and test outputs. See the

following sections for screen and function information.

To access the diagnostics menus while the applicator is running, press [RETURN] button on the

controller keypad.

View Inputs

Use the arrow buttons to scroll to the menu.

Use the arrow buttons to select [DISPLAY INPUTS].

NOTE: The number (1) indicates ON and the number (0) indicates OFF.

The current inputs are:

Controller Name Description

IN00 Tamp Home Tamp home sensor on tamp cylinder

IN01 Product Detector Product detector input

IN02 Print End Print end signal from print engine

IN03 Tamp Enable Tamp enable switch (optional)

IN04 Variable Tamp Tamp extended sensor on tamp pad

IN05 Media Out/Printer Error Wire-or of label out, ribbon out, error, signals from the print engine

IN06 Low Label Supply Input from low label sensor

IN07 Label On Pad Vacuum sensor on tamp pad

IN08 Start External Input Signal

IN09 Reset Applicator Disable External Input Signal

IN10 Not Used -----

IN11 Low Ribbon Ribbon low signal from the print engine



Test Outputs


Use the arrow buttons to selectively turn each signal ON and OFF.

The current outputs are:

Controller Name Description

OUT00 Error Applicator is in idle or Error mode

OUT01 Ready Applicator is in Run mode

OUT02 Label-on-Pad A label is present on the tamp pad

OUT04 Print Start Printer control signal

OUT05 Warning Low supply condition

OUT06 Tamp Error Tamp moved off home position unexpectedly

OUT07 Air Assist

OUT08 Air Blast

OUT09 Tamp

OUT10 Vacuum Control Supplies vacuum to the applicator

Cycle Time

The cycle time feature automatically extends and retracts the tamp assembly and measures the

amount of time of time of each action takes in milliseconds. The times are displayed on the

controller

This feature is useful in adjusting the tamp cylinder flow and cushion controls to ensure the

tamp assembly does not exceed rated speeds.

Test Cycle

The test cycle is a way to check all the machine functions as they go through a normal operating

cycle.


Use the arrow buttons to select [RUN] for a test cycle.

Return Button

The [RETURN] button on the controller keypad will clear errors once the condition causing them is

corrected. The applicator will then be placed into run mode.

Chapter 6




7 Maintenance

This section gives instruction for performing maintenance on the Model

4300 Printer-Applicator. Refer to the Print Engine Manual for

instructions on performing maintenance on the print engine.

Daily Maintenance

1. Clean the print head and platen roller each time you change the ribbon. Refer to the

Print Engine Manual for detailed instructions.

2. Examine filter-regulator for evidence of excessive water or oil collection. Drain and

eliminate the source of water/oil if possible. Maintenance to this filter will be greatly

reduced if you use an adequate pre-filter. This pre-filter should have a minimum flow

rate of 10 SCFM (283.17 liters) at 100 PSIG (6.2 bar) and be rated at a maximum of

10 microns.

3. Examine the tamp, vacuum grid, and peeler bar for excessive adhesive build up. Clean if

necessary, using alcohol or some other similar solvent.

4. Check the machine for any evidence of loose screws, rollers, fixtures, etc.

Overview

Chapter 7


Weekly Maintenance

1. Clean the peeler bar and tamp pad using alcohol or some other similar, compatible

solvent.

2. Clean dust from the product detector and low label detector lenses.

NOTE: Do not use air pressure from the shop air supply to blow dust from the

machine. There is a possibility that this air can contain water and emulsified oil,

which can damage the electrical components in the machine.

3. Examine air supply connections for leakage, correct if necessary.

4. Wipe down the exterior surfaces of the machine.

5. Examine all roller assemblies for free rotation, excessive play, etc., and correct as

necessary.

Maintenance


Six-month Maintenance

1. Replace the air filter elements and clean the filter bowl in the filter regulator.

NOTE: Do not use air pressure from the shop air supply to blow dust from the

machine. There is a possibility that this air can contain water and emulsified oil,

which can damage the electrical components in your machine.

2. Clean the inside and outside of the machine enclosure using an industrial vacuum

cleaner.

3. Check the tamp home sensor adjustment. (Refer to Tamp Home Sensor Adjustment.)

4. Check tension of unwind and rewind dancer arms. Adjust if loose.

5. Check urethane stop collars on tamp assembly. Replace if worn.

6. Check pneumatic tubing for cracks or wear. Replace if worn.

Chapter 7


Yearly Maintenance

1. Check all the items in the weekly and six-month maintenance sections.

2. Examine moving parts for excessive wear.

3. Check the drive belt for wear and proper tension.

Maintenance


Tamp Home Sensor Adjustment

NOTE: THE TAMP HOME SENSOR ADJUSTMENT SHOULD ONLY BE

PERFORMED BY A QUALIFIED SERVICE TECHNICIAN.

RIGHT-HAND

MOUNTING

SCREWS

Figure 7-1: Tamp Home/Extend Sensor Adjustment

When the tamp home sensor detects that the tamp has returned, the printer receives a signal to feed and

print the next label. The sensor has a small LED that indicates when the tamp is in the home position.

The sensor may need to be readjusted periodically, or whenever the tamp height is adjusted.

Tamp Home Sensor

Chapter 7


If the sensor does not indicate when the tamp is in the home position, use the following procedure to

adjust:

1. Disconnect the air supply from the applicator.

2. Loosen the sensor adjustment screw.

3. Push the tamp into the fully home position.

4. Adjust the sensor as required until the LED turns on. Tighten the sensor adjustment

screw.

NOTE: Be careful not to over tighten or the screw will strip.

Rewind Flag and Sensor Adjustments

.040/.030

NUT SUPPLIED WITH SENSOR TIGHTEN UP TO 24/20 LB/IN.

LOCK WASHER SUPPLIED

WITH SENSOR

LOCK WASHER SUPPLIED

WITH SENSOR

NUT SUPPLIED WITH SENSORTIGHTEN TO 24/20 LB/IN.

.000/.010 GAP FROMLEADING EDGE OF

O.D. OF SENSOR


Overview

8 Troubleshooting

This chapter covers diagnostic and troubleshooting information. It

explains how to use the built-in diagnostic tools and covers common

problems, possible causes and solutions.

PROBLEM POSSIBLE CAUSE SOLUTION

Label liner breaks Incorrectly threaded labels. Re-thread the labels.

Damaged roll of labels:

Nicks or label cutter die damage on liner.

Bruise on the side of the label roll.

Liner width varying significantly.

Replace the Label roll.

Adhesive buildup on peeler bar. Clean as necessary and examine label roll for damage. A damaged roll can cause excessive buildup. Replace label roll if necessary.

Labels are not being held onto the tamp pad. Label placement on the tamp pad is consistently poor.

Vacuum pump not operating. Check for air coming out of the muffler. Repair/replace as needed.

Vacuum too low. Refer to setup instructions.

Air assist too high or too low. Refer to setup instructions.

Air assist tube out of position. Refer to setup instructions.

Tamp pad holes not punched out.

Refer to setup instructions.

Label placement on the product consistently poor.

Product is inconsistently presented to the tamp pad.

Check to make sure that the conveyor speed is constant. Adjust guide rails or other product control devices to present the product in a consistent manner.

Incorrect tamp extend time. Refer to setup instructions.

Air-Blast too high or too low. Refer to setup instructions.

Chapter 8



Label placement on the product consistently poor.

Incorrect Air-Blast time. Refer to setup instructions.

Product detector sensitivity out of adjustment.


Product detector or reflector loose and vibrating.


Marginal detector position or adjustment.


Fluctuation in product conveyor speed.

Investigate and correct.

Poor quality of label adhesive. Replace the label roll.

Air assist does not function or is ineffective.

Air assist flow too low or too high.


Vacuum incorrectly set.

Air assist tube incorrectly positioned, damaged or disconnected.

Examine, adjust, repair, or replace as necessary.

Labels incorrectly threaded. Refer to setup procedures. Make sure that the label liner is threaded between the air assist tube and the peeler bar.

Air assist solenoid malfunction. Examine and replace if necessary.

Applicator controller malfunction.

Request qualified assistance.

Machine will not cycle. Printer jam. Clear obstruction and re-thread labels.

Tamp home switch not functioning.

Adjust the switch or replace if defective.

No product detection. Product detector I/O board jumpers not configured correctly.

Re-adjust the product detector; replace if defective. Check JMP2 settings on I/O board, see Chap. 9, Appendix for details.

Incorrect print engine parameter values.

Refer to the print engine manual for more information.

No labels to print. Send label printing information to the print engine buffer. (See print engine manual for more information.)

Applicator still in Idle mode. Press [] on controller to enter Run mode.

Troubleshooting



Label application rate unable to keep up with the product rate.

Product conveyor running too quickly for label application rate.

Check machine specifications for rate versus size of label being applied. Slow down conveyor if necessary.

Excessive printer processing time.

Check the software and compiling/editing time, and print speed. (See print engine manual for more information.)

Incorrect setup adjustments. Refer to setup instructions.

Machine functions occur at random without being initiated.

Product detector loose or vibrating.

Investigate and correct as necessary.

Product detector alignment or adjustment is marginal.


Loose wiring connections. Check all wiring connections. If necessary request qualified assistance.

No label feed. Tamp home sensor is broken or out of adjustment

Replace or adjust sensor as needed.

Print engine configuration incorrect.

Make sure that all the required parameter values are correctly entered in the print engine. Refer to the print engine manual for more information.

No labels to print. Load print information into the buffer.

Compressed print on labels in the feed direction.

Applicator unwind brake preventing labels from unwinding properly.

Reduce the tension of the dancer arm brake.

Poor print quality. Refer to the print engine manual.

Refer to the print engine manual.

Labels print continuously without being applied.

Print engine configuration incorrect.

Make sure that all the required parameter values are correctly entered in the print engine. Refer to the print engine manual for more information.

Air-Blast does not occur. Air-Blast time too short. Refer to setup instructions.

Air-Blast solenoid malfunction. Investigate and replace if necessary.

Label fails to leave the tamp. No Air-Blast. See solutions above.

Too much vacuum. Refer to setup instructions.

Air-Blast too low. Refer to setup instructions.

Rewind motor stalls and fails to rewind label liner waste.

Rewind sensor flag is out of alignment.

Refer to Rewind Sensor Flag Adjustment section in Chapter 8.

Chapter 8




9 Appendix

This chapter contains the following additional information for

the applicator:

Product Detector Jumpers

Stack Light

External Tamp Disable Switch

I/O Interface

Trigger Signal Usage

Input Connection Examples

Outputs Specifications

Output Connection Example

AC Wiring

DC Wiring

Redundant System Feature (aka Zero-Downtime)

Pneumatic Schematic

Center of Gravity Drawings

CE Declaration of Incorporation

CE Declaration of Conformity

Overview

Chapter 9


Product Detector Jumpers

The product detector triggers a label application cycle. JMP2 on the rear of the Model 4300 IO board

is used to configure the product detector input. The product detector connects to the product detector

receptacle located on the rear of the Model 4300 enclosure. The receptacle is a 5-conductor, M12,

female connector that accepts 4-conductor and 5-conductor cables terminated with an M12 male

connector.

Figure 9-1: Rear View of Enclosure with Call-Out to Product Detector

Pin Number

Allowed Connections

1 +24 VDC

2 Sink or source input

3 O VDC

4 Source or sink input

5 No connection

PRODUCT DETECTOR

Appendix


JMP2 Settings

Figure 9-2: Rear View of IO Board with Call-Out to JMP2

Jumper Position

Product Detector Output Configuration

1-2 Sourcing (PNP) on Pin 2 (Factory Default Position)

3-4 Sinking (NPN) on Pin 2

5-6 Spare Jumper Position

7-8 Sourcing (PNP) on Pin 4

9-10 Sinking (NPN) on Pin 4

Chapter 9


Stack Light

The stack light is an optional device available for the Model 4300. Weber offers two color

configurations: A single yellow light or a three-color green-yellow-red light.

Stack Light Color Code

green - solid normal operating condition

yellow - blinking low label or low ribbon supply

red-blinking idle mode

machine error

out-of-label

out-of-ribbon

The low label alarm monitors the supply of labels on the applicator unwind. The alarm trip

point is adjustable and may require adjustment. See Chapter 5, Low Label Sensor section for

sensitivity adjustment instructions.

Weber Circuit Stack Light Specifications

LED-type stack lights should be used with maximum current draw of 100 mA, 24 VDC

Voltage 24 VDC

Maximum

current per light 100 mA

Pin 1 +24V Common to all lights

Pin 2 ERROR, Red stack light

Pin 3 WARNING, Yellow stack light

Pin 4 READY, Green stack light

Receptacle: Male connector, M12, 4-pin

Appendix


External Tamp Disable Switch

A SPDT switch may be connected to Terminal Block 1 (TB1) pins 1 and 2 to implement and

external tamp disable switch. When the switch is closed, +24VDC power is applied to the tamp

valve solenoid. When the switch is open, +24VDC power is removed from the tamp valve

solenoid and the Model 4300 enters Idle mode.

To use the switch, the shorting block SB-1 must be cut on the I/O board. Use caution when

cutting the copper trace as to not cut any other traces.

Figure 9-3: Rear View of IO Board with Call-Outs to TB1 and SB1

Chapter 9


I/O Interface

Use the IO Interface to coordinate operation of the Model 4300 with external control systems.

The interface signals are available at a 25-pin female connector located on the rear of the

Model 4300 enclosure.

PRODUCT DETECTOR

Figure 9-4: Rear View of Enclosure

I/O Connector Pin-out

INPUTS SIGNAL NAME

Pin 1 +24 VDC (100 mA)

Pin 13 0 VDC (Signal Ground)

Pin 17 Trigger Apply

Pin 18 Trigger Print

Pin 19 Applicator Disable

Pin 23 Start

Pin 25 Input-Common

OUTPUTS SIGNAL NAME

Pin 2 Tamp Error (Normally Open)

Pin 3 Tamp Home (Normally Open)

Pin 4 Tamp Error (Common)

Pin 16 Tamp Home (Common)

product detector

master slave stack light

I/O connector

Appendix


Pin 10 Label-On-Pad (Normally Open)

Pin 14 Label-On-Pad (Common)

Pin 12 Data Ready (Normally Open)

Pin 15 Data Ready (Common)

Pin 11 Warning (Normally Open)

Pin 24 Warning (Common)

Pin 9 Ready (Normally Open)

Pin 22 Ready (Common)

Pins 5, 6, 7, 8, 20, and 21 have no connection.

Inputs Specifications

Optically isolated bipolar (polarity independent)

Input voltage 12 - 30 VDC

Trigger Apply

Triggers the application of a previously printed label waiting on the tamp pad.

Trigger Print

A trigger printing of a single label given a print job is waiting in the printer.

Chapter 9


Trigger Signal Usage

Mode Product Detector

Trigger Apply

Trigger Print

Notes

Tamp Blow


Tamp Blow PA Print and Apply Label



Tamp Blow PA Apply Label Apply Label Print Label Separate signals to print and apply a label.

Air Blow


Air Blow PA Print and Apply Label



Air Blow PA Apply Label Apply Label Print Label Separate signals to print and apply a label.

Inverted Tamp Blow


Start

Puts the Model 4300 in Run mode from Idle mode. If an error condition caused the Model 4300

to enter Idle mode, the Start signal will not return to Model 4300 to Run mode until the error

condition is corrected.

Applicator Disable

Dynamically switches the Model 4300 between Run and Idle mode. When a voltage is applied

to the input, the Model 4300 enters Idle mode. When the voltage is removed, the Model 4300

enters Run Mode.

Appendix


Input Connection Examples

Figure 9-5: Examples of Model 4300 Inputs

Chapter 9


Outputs Specifications

Optically isolated MOS relay

Maximum switching voltage: 40 VDC

Maximum current: 400mA continuous

Ready

The Model 4300 is in Run mode and ready to print and apply labels.

Tamp Home

The Model 4300’s tamp pad is in the Home position and ready to accept a printed label.

Label-On-Pad

A printed label is present on the tamp pad.

Warning

Label or ribbon supply is low.

Tamp Error

The tamp pad was physically moved off the home position by some means other than the Model

4300 control system.

Data Ready

The printer contains an active print job.

Appendix


Output Connection Example

Figure 9-6: Example Model 4300 Output

Chapter 9


AC Wiring

GREEN/YELLOW

CHASSIS

GROUNDWHITE

LIGHT BLUE

TRANSFORMER ASSEMBLY

(#54372)

2 3

1 4

GREEN/YELLOW

1 2

L

N

5 6

7 8 11 12

BROWN

BLACK

REWIND MOTOR/POWER

SUPPLY PCB ASSEMBLY

(#55025)

J2 J1

RE

D

RE

D

VIO

LE

T

VIO

LE

T

BROWN

LIGHT BLUE

A.C. WIRING DIAGRAM

L

PE

N

L

N

POWER ENTRY

MODULE ASSEMBLY

(#54373)

FUSES:

115 VAC MACHINES: 5A, 250V

230 VAC MACHINES: 2.5A, 250V

AUXILIARY POWER

OUTLET

(#54013)

Figure 9-7: AC Wiring

Appendix


DC Wiring

LOW-LABEL SENSOR

#55138

TAMP HOME SENSOR

#56124

LABEL-ON-PAD SENSOR

#56024

VARIABLE TAMP SENSOR

#56050

OR

TAMP EXTEND SENSOR

#56124

REWIND/24VDC PCB

#55025J3

CABLE #55132

4300 CONNECTOR BOARD

#56010

J4

CABLE #56110

PRINTER I/O CABLE FOR SATO

#54396

PRINTER I/O CABLE FOR ZEBRA

#54387

J4 LOW

J2 HOME

J3 LOP

J11 VT

J13

POWER

J5J6

J7

J18

ZEBRA/DMX SATO

PNEUMATIC BLOCK

HARNESS #56142

PD SENSOR

JMP2

Figure 9-8: DC Wiring

Chapter 9


Redundant System Feature (aka Zero-Downtime)

The Model 4300 supports a simple redundant system feature where the Ready output from one

applicator (primary) is connected to the Applicator Disable external input of another applicator

(secondary.)

When the primary applicator is ready and applying labels the secondary applicator is held in Idle mode

and not applying labels. When the primary applicator becomes not ready due to an error condition, the

secondary applicator automatically switches to run mode and applies labels. Once the primary

applicator’s error condition is corrected and the applicator is ready, the secondary applicator will

automatically switch to Idle mode and stop applying labels.

To use this feature, one Model 4300 is configured as a ‘Master’ and one Model 4300 is configured as a

‘Slave.’ Next, a signal cable is connected between the two Model 4300s. Connect Weber cable #56138

to the Master-Slave connectors on the rear of the Model 4300 enclosure.

To configure a Model 4300 for Master or Slave, turn off power and remove the power cord from the

model 4300. Next, remove the cover on the enclosure and located the printed circuit board attached to

the rear of the enclosure. On the back side of the circuit board is a jumper label Master and Slave. Set

the jumper to Master or Slave. Note the factory setting is Master.

Load both printers with a print job and place both printers in Run mode. The Slave Model 4300 will

enter Idle mode and wait until the Master Model 4300 is unable to print labels.

Figure 9-9: Connector Board with Callout to Master Slave Jumper

Appendix


Pneumatic Schematic

VAC

VAC

VSOAA

IN

ACI

X X

BLANK

PNEUMATIC SCHEMATIC

EXH

AB

2CYL

AB

TP

AATP

EXH

42

Figure 9-10: Pneumatic Diagram

Chapter 9


Center of Gravity Drawings

C OF UARM

PIVOT

MOUNTING

L

C OF UARM

MOUNTINGL

-110 PAX 4

-NO MEDIA ON UNWIND

-NO LINER ON REWIND

-3" STROKE

-4"x6" PAD

Figure 9-11: Center of Gravity

Appendix


Figure 9-12: Center of Gravity

Chapter 9


CE Declaration of Incorporation

CE Declaration of Conformity


10 Warranty

Weber Warranty Statement 4300 Applicator

Weber warrants the applicator to be free from defects in workmanship and materials for the specified

warranty period.

Applicator: The warranty period is one (1) year plus ten (10) days (total three hundred seventy

five (375) calendar days) from date of shipment from Weber, Arlington Heights based

upon an eight (8) hour work day and a five (5) day work week.

Print Engine: The print engine warranty period is ninety (90) days plus ten (10) days (total one

hundred (100) calendar days) from date of shipment from Weber, Arlington Heights

based upon an eight (8) hour work day and a five (5) day work week.

This warranty covers items that are defective in nature and does not cover neglect, abuse, misuse, or

natural acts. It does not cover equipment or parts that are improperly installed or replaced by the user

and/or his agent. It does not cover loss or damages resulting from accident, unapproved modifications,

or alterations. Normal maintenance must be performed in a timely and appropriate manner and all

supplies and/or replacement parts must be equivalent to those supplied by Weber. The warranty does

not cover expendable and/or consumable items or parts such as, but not limited to, labels, ribbons, or

print heads.

Warranty labor, travel and out of pocket expenses are covered for the first 100 days from date of

shipment when the equipment is installed by Weber Authorized Service Personnel dispatched by

Weber, Arlington Heights and the installation fees charged to the customer are at the normal

installation rates. It is not covered beyond the first 100 days from date of shipment. It is also not

covered if someone other than a Weber Authorized Service Personnel dispatched by Weber Corporate

performs the installation or if a reduced installation rate is used.

Limitation of Liability

Weber's responsibility shall be to repair or replace the product. It is limited to the invoice price of the

product claimed to be defective and is the sole remedy should the equipment fail to conform to this

warranty. Weber shall not be liable for any loss or damage of any kind, including any incidental,

special or consequential damages resulting, directly or indirectly, from any breach of warranty,

express or implied, or any other failure of this product.

This non-transferable warranty is limited to the original purchaser of the system and supersedes all

other warranties, expressed or implied, and shall not be modified in any way. No salesperson,

representative, or agent of Weber is authorized to make any guarantee, warranty, or representation that

contradicts this product warranty as published by Weber, Arlington Heights, IL. Any waiver,

alteration, addition, or modification to the published Weber warranty must be in writing and signed by

an executive officer of Weber to be valid.

Chapter 10




11 Index

AC Power, 4-1

AC Wiring, 9-12

Active Edge, 6-5

Adjustment

low label sensitivity, 4-16

low label sensor, 4-15

Adjustments Menu

active edge, 6-5

trigger count, 6-4

vacuum shutoff, 6-4

Air Assist Adjustment, 4-2

Air Filter, 3-11

Air Pressure

tamp adjustment, 4-9

Applicator

positioning, 5-1

setup, 4-1

CE Declaration of Conformity, 9-18

CE Declaration of Incorporation, 9-18

Center of Gravity Drawings, 9-16

Components, 2-5

Compressed Air, 4-2

Compressed Print, 8-3

Configuration

tamp blow, 3-8

tamp blow flag, 3-10

Controller Keypad, 6-3

Controller Operation, 6-1

Conventions, 1-1

Customer Support, 1-4

Daily Maintenance, 7-1

DC Wiring, 9-13

Detector Sensitivity Setup, 5-1

Diagnostics, 8-1

Diagnostics Menu, flowchart, 6-4, 6-8

Emergency Stop Function, 2-2

E-Stop Function, 2-2

External Tamp Disable Switch, 9-5

Flowchart

applicator menu, 6-1

diagnostics menu, 6-4, 6-8

General Information, 2-1

I/O Interface, 9-6

Information

general, 2-1

Input Connection Examples, 9-9

Introduction, 1-1

Label

alignment, 4-5

liner breaks, 8-1

placement, 8-1

width setting, 3-6

Low Label

alarm trigger point, 4-18

sensitivity adjustment, 4-16

Low Label Sensor

adjustment, 4-15

trigger point, 4-18

Low Label Sensor Trigger Point, 4-18

Machine Attitudes, 4-19

Machine Layout, 2-5

Machine Placement

criteria, 2-2

safety, 2-2

Machine Position, 2-2

Machine Settings Menu

start-up delay, 6-6

Machine Stand, 2-2

Maintenance

daily, 7-1

six-month, 7-3

weekly, 7-2

yearly, 7-4

Manual Outline, 1-3

Moving Printer, 3-4

Output Connection Example, 9-11

Outputs Specifications, 9-10

Placement

machine, 2-2

Pneumatic Schematic, 9-15

Positioning the Applicator, 5-1

Power Supply

connection to AC power, 4-1

Preliminary Setup, 3-1

Chapter 11


Product Detector

Adjustments, 5-1

Postion, 5-1

sensitivity setup, 5-1

Setup, 5-1

Product Detector Jumper, 9-2

Product Detector Position, 5-2

Redundant System Feature, 9-14

Return Button, 6-9

Ribbon and Label Loading, 3-5

Rotatable Display, 4-21

Setup

air filter, 3-11

tamp pad, 3-7

unpacking, 3-2

Setup, preliminary, 3-1

Six Month Maintenance, 7-3

Specifications, 2-1

Stack Light, 9-4

Start-Up Delay, 6-6

Static Stack Test, 4-12

Tamp

home adjustment, 4-3

Tamp Adjustment, 4-9

Tamp Blow Flag Configuration, 3-10

Tamp Home Sensor Adjustment, 7-5, 7-6

Tamp Pad

label alignment, 4-5

punching instructions and safety, 3-7

tamp blow configuration, 3-8

Tamp Pad Setup, 3-7

Technical Support, 1-4

Test Run, 5-2

Trigger Count, 6-4

Trigger Signal Usage, 9-8

Troubleshooting, 8-1

Unpacking, 3-2

Vacuum Shutoff, 6-4

Warranty, 10-1

Weekly Maintenance, 7-2

Yearly Maintenance, 7-4

Zero Downtime, 9-14

model 5200 printer-applicator - weber packaging

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