Original Instructions

Installation, Setup, Operation and Maintenan-

ce/Servicing

Legi-Air 4050I
Article number of documentation 40001851

Copyright ©, Weber Marking Systems GmbH

Weber Marking Systems GmbH Version: 10.12.14 /ZIM

Maarweg 33
D-53619 Rheinbreitbach
E-Mail: info@[Link]
[Link] 40001851
Blank Page
Content 40001851 BTA Legi-Air 4050I

Table of Contents

1.  General Information .............................................................................................. 6 

Overview ..............................................................................................................................6 
Limitation of liability ..............................................................................................................6 
Warranty conditions .............................................................................................................6 
Copyright protection .............................................................................................................6 
Purpose and scope of this manual .......................................................................................6 
Hints for use of this manual .................................................................................................7 
Service-Hotline .....................................................................................................................8 
Explanation of technical terms .............................................................................................9 

2.  Safety Regulations .............................................................................................. 13 

Behavior in case of an emergency .....................................................................................13 
General safety regulations .................................................................................................13 
Explanation of degrees of danger ................................................................................................ 13 
Intended use ......................................................................................................................14 
Reasonably foreseeable misuse ........................................................................................15 
Retrofitting and changes at the labeling system ................................................................15 
Hazards to the labeling system ..........................................................................................16 
Legi-Air 4050I CC (with CE-mark) ............................................................................................... 17 
Legi-Air 4050I NC (without CE and without limitation of the tamp force to 50N) ......................... 17 
Warnings on the labeler .....................................................................................................18 
Remaining risks .................................................................................................................18 
Waste disposal ...................................................................................................................18 
Safety instructions ........................................................................................................................ 19 
Obligations of the operator .................................................................................................21 
Authorized persons ............................................................................................................21 
Personal protective gear ....................................................................................................22 
Protection Devices .............................................................................................................23 
Separative and non-separative protection device ........................................................................ 23 
System cover ............................................................................................................................... 23 
Emergency stop function ...................................................................................................24 
Turning off the air pressure .......................................................................................................... 24 
Function of turning off the air pressure ........................................................................................ 24 
Turning on the air pressure .......................................................................................................... 25 
Air pressure monitor ..................................................................................................................... 25 
Working places operator personnel ...................................................................................25 

3.  Technical Specifications .................................................................................... 26 

Information on further dimensions ............................................................................................... 26 
Performance data......................................................................................................................... 26 
Information on operation .............................................................................................................. 27 
Noise level .................................................................................................................................... 27 
Information on compatible print engine types .............................................................................. 27 

4.  Description of the labeler ................................................................................... 28 

Function and application field of the labeler .......................................................................28 
Complete overview Legi-Air 4050I .....................................................................................29 
Figure: Legi-Air 4050I in righthand version (RH) ......................................................................... 29 
Figure: Legi-Air 4050I-versions in different installation positions (RH/LH) .................................. 31 
Figure: Legi-Air 4050I side views (LH/RH)................................................................................... 32 

Version: 10.12.14 Page 3 of 101 GB

Content 40001851 BTA Legi-Air 4050I

Figure: Legi-Air 4050I rear side (RH / LH) ..................................................................................33 

Application modes ..............................................................................................................34 
Tamp-Blow-Mode ......................................................................................................................... 34 
Tamp-On-Mode ............................................................................................................................ 34 
Management of printing data .............................................................................................34 
Batch operation (Batch processing) ............................................................................................. 34 
On-demand operation (Single processing) .................................................................................. 34 

5.  Transport ............................................................................................................. 35 

Delivery ..............................................................................................................................35 
Scope of delivery.......................................................................................................................... 35 
Transport and unpackaging ...............................................................................................35 
Safety regulations ........................................................................................................................ 35 
Storage conditions .............................................................................................................37 

6.  Installation and initial startup ............................................................................ 38 

Safety regulations ........................................................................................................................ 38 
Installation ..........................................................................................................................40 
Requirements to the installation site ............................................................................................ 40 
Placing the labeling system ......................................................................................................... 40 
Setting up the labeling system ...........................................................................................41 
Connecting the labeling station ..........................................................................................41 
Overview of the connections at the labeler ........................................................................42 
Connection to supply voltage ....................................................................................................... 43 
Connection to compressed air ..................................................................................................... 44 
Connection and positioning of the product sensor ....................................................................... 45 
"Display" -connection ................................................................................................................... 46 
"Low label sensor" -connection .................................................................................................... 46 
Low label warning (Low label) ...................................................................................................... 46 
"USB" - interface .......................................................................................................................... 46 
"Applicator" -connection ............................................................................................................... 46 
"Alarm lamp" -connection ............................................................................................................. 47 
"Printer" -connection .................................................................................................................... 47 
Print engine setup (Printer) .......................................................................................................... 47 
"Interface" (I/O-User interface) .................................................................................................... 48 
Label and ribbon loading ....................................................................................................51 
Ribbon loading ............................................................................................................................. 51 
Label loading ................................................................................................................................ 51 
Initial operation ...................................................................................................................53 
Safety regulations ........................................................................................................................ 53 

7.  Operation ............................................................................................................. 54 

Operation of the labeler .....................................................................................................54 
Safety instruction.......................................................................................................................... 54 
Opening and closing the cabinet’s door ....................................................................................... 54 
Temperature setting for swich cabinet heatings (Option) ............................................................ 55 
Manual operation of pneumatic slide ........................................................................................... 57 
Turn on and off labeler ................................................................................................................. 57 
Start labeling operation ................................................................................................................ 58 
Stop labeling operation ................................................................................................................ 59 
Putting the system out of service .......................................................................................59 
Operation of the display-controller .....................................................................................60 
Functions of the operator buttons ................................................................................................ 60 
Status-LEDs ................................................................................................................................. 61 
Program menus .................................................................................................................61 

Version: 10.12.14 Page 4 of 101 GB

Content 40001851 BTA Legi-Air 4050I

Indication of firmware version ...................................................................................................... 61 

Current configuration set .............................................................................................................. 61 
Label counter ............................................................................................................................... 62 
Status line .................................................................................................................................... 62 
DISPLAY SETTING ..................................................................................................................... 65 
EVENT COUNTER ...................................................................................................................... 66 
CYCLE SEQUENCE .................................................................................................................... 67 
CONFIGURATION-Menu ...................................................................................................68 
PASSWORD: 000 ..................................................................................................................... 69 
PRINT TRIGGER : 001 ............................................................................................................. 69 
LABEL TIMEOUT: 255 .............................................................................................................. 71 
VACUUM LEVEL: 005 ............................................................................................................. 71 
VACUUM TIMEOUT: 200 .......................................................................................................... 72 
EXTENS-TRIGGER : 000 ........................................................................................................... 72 
EXTENSION DELAY: 000........................................................................................................... 73 
EXTENSION TIME: 080 ............................................................................................................. 74 
PROXIMITY TIMEOUT: 000 ....................................................................................................... 75 
BLOW-TRIGGER: 000 .............................................................................................................. 76 
BLOW DELAY: 000 ................................................................................................................ 77 
BLOW TIME: 050 .................................................................................................................. 77 
HOME TIMEOUT: 000 .............................................................................................................. 78 
SYNC PULSE DELAY: 000 ...................................................................................................... 78 
SYNC PULSE TIME: 005 .......................................................................................................... 79 
BARCODE RD TIME: 000 ........................................................................................................ 80 
CYCLE OPTIONS: 000 ............................................................................................................. 81 
Parameter list of configuration CFG 0-3.............................................................................82 
PROGRAMMING ...............................................................................................................83 
DIAGNOSTICS ..................................................................................................................83 
Firmware History ................................................................................................................84 

8.  Maintenance/Service ........................................................................................... 85 

Safety regulations ........................................................................................................................ 85 
Daily maintenance/service (After approx. 8 hours of operation) .................................................. 86 
Weekly maintenance/service (After approx. 40 hours of operation) ............................................ 87 
Six-Month maintenance/service (After approx. 1000 hours of operation) ................................... 88 
Yearly maintenance/service (After approx. 2000 hours of operation) ......................................... 88 
Spare parts ........................................................................................................................89 
Wiring- and pneumatic diagrams .......................................................................................89 
Cleaning Notes............................................................................................................................. 89 

9.  Troubleshooting .................................................................................................. 91 

Mechanic failures ...............................................................................................................91 
Error messages via display ................................................................................................94 
Error Reset ................................................................................................................................... 94 
Status messages via display ..............................................................................................97 

10.  Index ..................................................................................................................... 99 

Catchwords from A to Z ............................................................................................................... 99 

11.  EC-Declaration of conformity........................................................................... 101 

Version: 10.12.14 Page 5 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

1. General Information

Overview
Congratulations! You have purchased a high-quality Printer-Applicator. Our concern is to
make sure that you profit from this system to your entire satisfaction over many years. In
order to ensure this, we strongly recommend you to let our experienced specialists per-
form the installation (hints s. page 40). Please contact our Service-Hotline (s. page 8), we
are available for you from Monday til Friday 24 hours.

Limitation of liability
All pieces of information and notes of this manual have been arranged in consideration of
applicable standards and regulations, state-of-the-art technology as well as our cognition
and experiences over many years.
The manufacturer assumes no liability for damages caused by:
¥ Non-observance of this manual
¥ Non-observance of the intended use
¥ Use of unqualified personnel
¥ Manipulations at the system
¥ Use of spare parts that are not approved by the manufacturer
The obligations of the supply contract the General Trading Conditions as well as the terms
of delivery of the manufacturer and the valid legal regulations at the moment of conclusion
of a contract generally apply. Technical changes within the scope of improvement and de-
velopment are subject to change without notice.

Warranty conditions
The warranty conditions are conform to the valid General Trading Conditions of Weber
Marking Systems GmbH at the moment of purchase.

Copyright protection
This documentation or parts of this documentation may only be copied, photocopied, re-
produced or translated into other languages for personal use. Without previous expressed
written permission of Weber Marking Systems GmbH a reproduction for circulation to a
third party is not permitted.

Purpose and scope of this manual

The manual is designed to become acquainted with the system and to be able to use the
system according to its specifications.
It provides important remarks for the user to operate the system secure and appropriate.
Its consideration assists to avoid dangers, to reduce repair costs and down times and to
increase the reliability and the durability of the system.
The manual is valid for the system described in the title with noted serial number.

Version: 10.12.14 Page 6 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

The manual has to be available every time at installation site of the system and has to be
read and applied by personnel performing work at the system.
Misprints, errors and state-of-the-art technology changes are subject to change without
notice. Figures may be stated without protection device for clarification.

Hints for use of this manual

Detailed explanations are offered below of the conventions for the text and illustrations
which are used in this manual.
¥ Buttons and switches that need to be pressed are placed in brackets.
Ex.: Press the [Start] button to accept the changes...

¥ Procedures that need to be performed in a fixed sequence have to be numbered.

Step Procedure
1 Pull the power plug...

¥ Special information is in bold and/or has a grey background.

This is an example of special information!

¥ All figures (Fig.) are numbered sequentially for each chapter. This means that the
reference "Fig. 2-1" corresponds to the first figure in chapter 2.
¥ Illustrations are frequently shown with only the essential information and may there-
fore deviate from the original. Illustrations are therefore shown without covers or pro-
tection device for the sake of clarity.
¥ To fulfill the product variety, example or principle figures may deviate significantly
from original or do not apply.
¥ Illustrations limit itself partly to the depiction of one variant (e. g. only RH, only
LH, system versions with or without optional assembly groups…). It is particularly
valid for example figures if the information content is transferred logically to other
system versions.
¥ Messages which appear on a controller *² display are shown in a text box:

AP4050.0 01234
WAIT LABEL 01
*² only if system has the appropriate feature

Version: 10.12.14 Page 7 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

Service-Hotline
The technical service hotline is available 24 hours a day, Monday through Friday. In
emergencies, parts may be shipped as late as approximately 10:00 p.m.
Tel : +49 (0)2224 - 7708 - 440
Fax : +49 (0)2224 - 7708 - 21
E-Mail : hotline-ed@[Link]

If failures at the labeling system occur, you should be prepared with following information
when being asked on the phone:
¥ Detailed error description.
¥ All information on the name plate of the labeler.
¥ When did the error occur for the first time?
¥ After loading new label material/ribbon?
¥ After changes in the setup of the labeler?
¥ All information about the PLC signals in case of a failure of a print-apply cycle.

Prior to call our hotline service, please have a look at the manual (chapter
"Troubleshooting’’) for potential references to eliminate the error.
Our main effort is to keep the service hotline always possibly free for urgent cases. How-
ever, we beg your pardon that our hotline also refers to written information provided in this
manual.

Version: 10.12.14 Page 8 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

Explanation of technical terms

Technical Term Explanation

Adhesive Strings Leaked adhesive at the label edge may adhere the label at
the label liner. The printed label adheres to the liner and can
thus not be fed to the tamp.

Air Assist A stream of air pushing against the bottom of the tamp/blow
box during label feed until label is fixed by vacuum.

Air Assist Tube The air assist tube directs air assist by one or more drillings
to the bottom side of the label. It is mounted in the section of
the peeler bar and can be adjusted.

Air Blast The streams of air effusing from the tamp drill holes during
labeling in order to blow the label by air pressure onto the
product (blow box by tube nozzles).

Application Mode see explanations: Tamp On, Tamp Blow, Blow On.

Applicator Description for label applicator respectively mimic that moves

the tamp.

Applying Cycle An entire working sequence of the labeler ((e.g. print label if
applicable), peeling off the label and feeding the label to the
applicator up to product labeling).

Automatic Operation See labeling operation

Bad Tag A "Bad Tag" is a defective transponder of an RFID label. This

tag could not be read and/or written.

Blow-On A contact free application mode in which the tamp takes the
printed label by a stationary vacuum grid and applies with air
pressure without moving the tamp.

Configuration Mode Mode, where parameters for applicator configuration can be

changed by display.

Contrast Difference in the brightness of light and dark sections of a

print.

Conveying System Complete unit consisting of conveyor belt and controller.

Conveyor Belt Assembly line for product transport.

CS Figreviation for conveying system (s. a.).

Cycle Sequence of a labeling procedure, from product detection to

product labeling until the tamp arrives in home position.

Default See factory setting.

DIP Switches DIP is the abbreviation for „Dual In-line Package“.DIP switch-
es are tiny switches with 4 to 8 pins. With these pins the in-
verter state can be changed (open/closed) by a sharp object
(e.g. pencil). The applicator configuration is determined by
the switch position.

Dancer Arm Arm, tensing the label web via spring tension.

Display Display providing information on status for the user.

Version: 10.12.14 Page 9 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

Technical Term Explanation

Edge Detection The edge (front or back) of a product or label that will cause
the detector to send a detection signal.

Factory Setting Comprises all basic adjustments of the system after manufac-
turing which may differ from the condition after a system set-
up. Software parameters are reset by a reset to the factory
setting (default values) and formerly adjusted values are lost.

Feed (Label Feed) The key [Feed] serves for transportation of a label.

Home Position Basic or home position of the tamp at the peeler bar.

Home-Position-Sensor Sensor for detection of home position when the tamp is in

home position.

Hotline Customer support for a fast diagnosis by phone.

Label Applicator Unit for applying labels.

Label Feed Feeding of a label. By pressing the [Feed] key of the print
engine, the drive motor is activated and transport of the label
web is started (dancer arm loosens the unwinder brake
band). The fed label is printed on within the print engine and
peeled off at the peeler bar.

Label Gap Gap between two labels on the label web. The gap is identi-
fied by a sensor on the applicator.

Label Gap Sensor See label sensor.

Label Liner Siliconized liner paper that the labels are affixed to before
they are applied to the product.

Label Out An optical sensor (reflective light sensor) for identifying the
end of the label.

Label Sensor An optical sensor for identifying the label gap.

Label Size Shows the label format width x length (in feed direction of the
label) in mm (millimeter).

Labeler Applicator system to apply labels automatically.

Labeling operation Normal operating conditions. The labeler is ready to print and
apply labels.

Leading Edge The front edge of the product/label that triggers the label ap-
plication (see also edge detection).

LED Light Emitting Diode.

Low Label Warning An optical sensor (reflective light sensor) for identifying a
preset minimum of the (adjusted) label roll diameter for a
warning.

Maintenance Unit (FR- Unit contains:

Air pressure regulator manometer for displaying the air pres-
Group)
sure value (in bar)
Fast Closing Valve
Water separator for draining the possible present perspiration
water manually

Mandrel A driven axis with a device for fixing the label web. The man-
drel serves for unwinding the label web.

Version: 10.12.14 Page 10 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

Technical Term Explanation

Manometer See maintenance unit.

Peeler Bar Metal edge of the applicator for peeling off the label. If the
labeler has also a print engine, the peeler bar is located be-
neath the print head.

Photocell Product sensor. The sensor identifies the product and acti-
vates the trigger signals. See trigger.

PLC Programmable logic controller.

Pneumatic Uses compressed air as energy source to create movements

and currents.

Poti / Potentiometer Changeable resistance (regulator) for analog regulation of

adjustments at the labeler (e.g. time performance of the tamp
movement depending on the rotational position of the poten-
tiometer).

Printhead Printhead of print engine. Tiny heating elements (dots) in the

printhead create warmth and transfer it using the ribbon to a
print media (thermal transfer) or using a color change in print
media (thermal direct).

Print job Label layout consisting of graphics, barcodes… print data

incl. controller commands (print quantity,- contrast, - speed…)
that has to be sent to printer by data interface.

Product-Sensor A sensor for detection of the product. Mostly, optical sensors

are used (photocells, light barriers or reflective sensors)
(Product Detector)

PSI The American measure of air pressure (Pounds per Square

Inch Gauge). 1 bar = 14.7 PSI.

Product Delay An adjustable delay time from detection of product until start
of the applying cycle.

Re- and Unwinder See re- resp. unwinder.

Rear Edge See trailing edge.

Reset Command for resetting software systems on default. Usually

activated by a certain key combination.

Rewinder Roll holder (normally for 3 inch cardboard cores) for rewind-
ing the label web. The rewinder winds up the web coming
from the print engine. It is triggered by a dancer arm (see
dancer arm). Rewinders are powered by a motor.

RFID This abbreviation stands for Radio Frequency IDentification

(Data readout via radio frequency). This technology is used
for marking in order to trace products by Smart labels (ref.
RFID Label).

Stroke Distance which the retracted tamp covers towards the prod-
uct.

Tamp A mechanical device that receives a label and moves the

label to a position where it is applied to a product.

Tamp Pad Drilled plate of the tamp on which the peeled off label is trans-
ferred.

Version: 10.12.14 Page 11 of 101 GB

Chapter 1 General Information 40001851 BTA Legi-Air 4050I

Technical Term Explanation

Tamp-Blow Contact free application mode where the tamp takes the
printed label by vacuum, feeds it to the product and blows it
on the product.

Tamp Movement Time Duration of the tamp movement (extension and retraction) at
labeling cycle.

Tamp-On Application mode where the tamp takes on the label by a

vacuum, feeding it and pressing it onto the product.

Thermal Element See printhead.

Touchscreen Touch-controlled touch screen, screen, monitor…

Trailing Edge The rear end of a product which is used for activating the
application (s.a. edge detection).

Transponder The transponder is part of a RFID label and is called Tag. It

consists of a micro chip with an antenna. This chip is able to
store data via radio frequency read and depending on its
construction can be written on. The antennae of the tran-
sponders are used as a transmitting as well as a receiving
aerial. Simultaneously it provides the required energy for the
chip by transforming energy of the emitted electric field from
the Reader into current power.

Trigger-Signal Signal of a sensor or a PLC, activating the application cycle.

Unwinder Roll or paper holders for rewinding or unwinding the print

medium (normally for 3 inch cardboard cores). The unwinder
enables a smooth-running unwinding without shock of the
label roll and is controlled by a roller brake (see also dancer
arm). Rewinder and unwinder can also be powered by mo-
tors.

VAC Volts AC (Alternating Current). Also designated as ~

Vacuum Generator (Ven- Unit using air pressure for creating a vacuum.
turi)

Variable Stroke Sensor A proximity sensor mounted on the tamp for identifying the
product. On identifying the product the label is either blown
on or peeled off.

VDC Volts DC (Direct Current).

Void-Signal Name for printer signal that is sent to the labeler when a Bad
Tag was detected.

Water Separator See maintenance unit.

Web Label web consisting of a siliconized liner and adhering la-

bels.

Version: 10.12.14 Page 12 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

2. Safety Regulations

Behavior in case of an emergency

The operating personnel have to be familiar with the operation and the location of safety-,
accident notification-, first aid- and rescue devices.

What to do in case of an emergency?

 If persons or parts of the body or items are jammed in swing parts of the labeler, sep-
arate the labeler immediately from air pressure and power supply.
 Initiate immediately all required emergency measures for injured persons. Observe
valid safety regulations in any case in order to avoid further damages to persons.
 Call medical attendance for injured persons.
 Eliminate all accident causes.

General safety regulations

Safety regulations provide information in written and symbol form in order to warn you
against dangers and to instruct you to avoid any damage to persons or to properties.
Safety regulations are started by signal words indicating the level of danger.
Safety regulations may be placed directly at the labeler or in documents about this labeler.

Explanation of degrees of danger

This symbol indicates a hazardous situation which, if not avoided,

will result in death or serious injury. All safety regulations have to
be observed to avoid any damage to persons.
This symbol indicates a hazardous situation which, if not avoided,
could result in death or serious injury. All safety regulations have to
be observed to avoid any damage to persons.
This symbol indicates a hazardous situation which, if not avoided,
may result in minor or moderate injury. All safety regulations have
to be observed to avoid any damage to persons.
This symbol indicates a hazardous situation which, if not avoided,
may result in damage to properties. All safety regulations have to
be observed to avoid any damage to properties.

Version: 10.12.14 Page 13 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Intended use

The working reliability of the labeler is ensured only with intended use.

An Intended Use applies, if …

¥ the labeler is used exclusively for automatic labeling of moved respectively stopped
products.
¥ maintenance is only carried out after stopping the labeler.
¥ the labeler is used with specified products as well as specified labels. Products and
labels have to meet all *documented specifications agreed upon between manufactu-
rer and customer.
* "documented specifications" are normally laid down in the LSS (Labeling Systems Survey) and handed out to the cus-
tomer with the confirmation of order.

¥ the labeler is operating in explosion-proof environments (not intended for explosion-

risk areas) !
¥ the labeler does not come in direct contact with food products.
¥ the labeler is not operating outdoors.
¥ the labeler is used with an additional pneumatic slide at the aperture for the tamp
when operating in a wet environment.
¥ the labeler has additional air conditioning features in the stainless steel cabinet for
use in an aggressive air environment (e.g. salted air).
¥ the labeler has additional air conditioning features in the stainless steel cabinet for
use in a dusty environment with unadjusted particles.
¥ the labeler is used exclusively for industrial purposes.
¥ all working conditions and instructions, prescribed in this manual, will be observed.
¥ failures at the labeler affecting the safety have to be reported and immediately re-
solved by trained and briefed personnel.
¥ maintenance is kept and performed correctly.
¥ the labeler is used exclusively under faultless conditions.
¥ safety equipment are not by-passed or abrogated.
¥ arbitrary changes at the machine are omitted.
¥ the labeler is used or operated by adequate personnel, refer to “Authorized persons”
(s. page 21). These persons must have read and have to be familiar with the content
of the manual.
Handling the labeling system without considering one of these points is not for the intend-
ed purpose and can cause serious damages to persons or properties.

Version: 10.12.14 Page 14 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Reasonably foreseeable misuse

Another use as fixed in the „Intended Use“ or even more applies as not intended!
For damages caused by not intended use:
¥ the operator bears the complete responsibility,
¥ the manufacturer assumes no liability.

If you do not use the system according to the regulations, risks may occur!

Not intended uses are e.g.:

¥ operation in exposable atmosphere
¥ the labeler comes in contact with food …

Retrofitting and changes at the labeling system

Unauthorized retrofitting and changes at the system lead to an immediate expiration of li-
ability and warranty covered so far by the manufacturer! This is also valid for interventions
and program changes at programmable control systems as well as program changes at
control units as far as they are not described in this manual.
The electromagnetic performance of the system can be affected by amendments or
changes of any kind.
Do not arrange any changes or amendments at the systems without consultation and writ-
ten approval of the manufacturer.

Version: 10.12.14 Page 15 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Hazards to the labeling system

Fig. 2-1: Hazards to the Legi-Air 4050I RH (Cabinet closed)

When the cabinet is closed, hazards may be caused by following assembly groups (e.g.:
pushing, crushing, shear blasting):
¥ Tamp, particularly at the aperture of the cabinet
¥ Pneumatic slide

Fig. 2-2: Hazards to the Legi-Air 4050I RH (Cabinet opened)

When the cabinet is opened, hazards may be caused by following assembly groups (e.g.:
pushing, crushing, shear blasting):
¥ Tamp, particularly at the aperture of the cabinet
¥ Pneumatic slide
¥ Entanglement hazard in the area of label re- and unwinder

Version: 10.12.14 Page 16 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Legi-Air 4050I CC (with CE-mark)

The arising forces at the Tamp are limited to 50 Newton for both movements of the stroke,
which may be potential risks of injury to persons classified as low (usually reversible).
Therefore additional protection measures (e.g. safety guards, protective cabinet…) are not
required. The limitation of the tamp force to 50 Newton is realized by regulator valves of
the internal pneumatic circuit.

A manipulation of the regulator valves can lead to cancellation of the conformity re-
ferring to the CE-declaration!
A change of the regulator valve adjustment may only be arran-
ged by authorized personnel.

If the tamp force exceeds 50N, further protective measures are

Fig. 2-3: Warning label inside required (s. b.).

Legi-Air 4050I NC (without CE and without limitation of the tamp force to 50N)
Following labeler without limitation of the tamp force to 50N, require additional pro-
tective measures for a safe operation:

 Legi-Air 4050I (NC) Tamp Blow or Tamp On

Considerable risks of injury exist!

By cancellation of the maximum force limitation of 50 Newton a safe operation of the
above-mentioned labelers is only possible by an additional protective measure incl.
pneumatic supply shutoff (ref. page 24).

Version: 10.12.14 Page 17 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Warnings on the labeler

Special hazards arising from the labeler are identified with yellow stickers. The pictograms
indicate hazards:

Danger

Life-threatening hazard due to electrical power

Crushing hazard

Entanglement hazard

Danger due to hot surface

Danger due to strong light radiation

Observe manual

Remaining risks
The labeler is constructed in a way that makes it safe for use. Some hazards are inherent
in the design and construction but can be minimized with the corresponding safety mech-
anisms and equipment. A certain residual risk always exists when operating machinery.
Knowledge about residual risks of the system helps you to increase your safety aware-
ness and avoid accidents. To prevent hazards, observe the special safety instructions and
each chapter.

Waste disposal

This label is in compliance with RoHS 2 EU Directive

2011/65/EU given observance of the prohibitions on use are and
avoidance of pollutants.

Version: 10.12.14 Page 18 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Safety instructions
Hazard from direct or indirect contact with voltage-
conducting parts.

DANGER TO LIFE!
When individuals touch parts that conduct electricity arising from
malfunctions
̶ Only electricians may work on the switch cabinet and electri-
cal equipment.
̶ Regularly check the electrical equipment of the labeling sys-
tem (see chapter “Maintenance/Service”).
̶ Immediately take care of loose connections and damaged
cables.
̶ Always keep the switch cabinet locked.
̶ Before working on electrical equipment, turn the miniature
circuit breaker to "0" position and secure it against being ac-
cidentally turned on. If possible, disconnect the power.

Hazard from easily flammable label material.

FIRE HAZARD!
The ribbon and labels are easily flammable. Potential injury from
fire and smoke.
̶ Keep away from sources of ignition and open fire.

Hazard from moved assembly parts.

RISK OF INJURY!
Entanglement- and crushing hazard due to pneumatically or mo-
tor-driven assembly parts of the labeler.
Motion sequences or rotations start in labeling operation sud-
denly and abruptly.
̶ Do not grip in, at or between the moving parts.

Danger to health from the improper use of lubricants and

cleaners.

HEALTH HAZARD!
Improper use may lead to health hazards.
̶ The instructions in the manufacturer’s current safety data
sheets for the specific lubricants and cleaners that are used
must be observed along with the applicable safety and dis-
posal regulations.

Version: 10.12.14 Page 19 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Danger caused by residual energy in pneumatic compo-

nents

RISK OF INJURY!
Flogging air pressure tubes, derailing parts or uncontrolled mov-
ing parts may cause injuries.
̶ Before connecting the air pressure, check all pneumatic con-
nections if they are fixed and fix them if applicable.
̶ The pneumatic system that should be maintained has to be
bled before the pneumatic components are dismantled.

Tripping hazard from connecting lines.

RISK OF INJURY!
Connecting lines for power, compressed air and computer and
signal lines can pose a tripping hazard, causing serious injury.
̶ Release the tension of connecting lines to the system and run
them so that they do not pose a hazard

Danger of injury from corners and edges.

RISK OF INJURY!
Scrapes and cuts can result from sharp edges and pointed cor-
ners. Always keep the work area clean.
̶ Observe caution when working close to sharp edges and
pointed corners. Remove unnecessary objects.
̶ In case of doubt, wear protective gloves.

Hazard from placed loads.

RISK OF INJURY!
Loads that are placed in or at the system cabinet can fall down
or lead to material fatigue.
̶ Do not place label rolls or similar loads in or at the system
cabinet.

Version: 10.12.14 Page 20 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Obligations of the operator

This manual is a part of the system and has to be available always within reach.
To guarantee a safe operation of the labeling station, the operator is obliged to …
¥ Ensure always the safety for the persons working at the labeling station.
¥ The technical data and information about the installation-, connection-, surrounding-
and operational conditions have to be observed consequently.
¥ The safety regulations that are special for the labeling station are observed.
¥ The use of personal protective gear is observed.
¥ Signposting and marking of hazard areas have to be renewed if damaged or lost.
¥ Personal to be trained or instructed or apprentices work only under constant supervi-
sion of experienced persons.
¥ All work at the electrical equipment is only arranged by qualified Electricians.
¥ All failures at the labeling station are repaired by trained personel or by Technicians
of the Bluhm Weber Group.
¥ The qualified personel is trained in handling the integrated controller before parame-
terizations may be arranged.
If you do not understand parts of this manual, we kindly ask you to contact imme-
diately your contact person at Bluhm Weber

Authorized persons
Authorized persons according to this manual are following persons:
Operators are persons who
¥ have been instructed to the use of the labeling system.
¥ have completed the minimum age permitted by law.
¥ have read and understood this manual
Operators are allowed
¥ to start or stop the labeling operation.
¥ to replace label or ribbon rolls.
¥ to arrange daily accumulating cleaning works at the labeling system according to the
chaper maintenance.
Qualified personnel are operators who
¥ have terminated a professional technical training (Electrician, Mechanist).
¥ have terminated a training at the Bluhm- Weber-Group successfully.
Qualified personnel are allowed
¥ to arrange repair- and maintenance works at the labeling station and its components

Version: 10.12.14 Page 21 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Personal protective gear

Wear the following protective gear when working on the machine:
PROTECTIVE FOOTWEAR
̶ To protect against falling parts and slipping

PROTECTIVE WORK CLOTHES

Protective work clothes fit snugly, tear easily, have tight-fitting
sleeves and no projecting parts
̶ Wear a hair net if necessary.
̶ Do not wear jewelry, wristlets, watches or similar
SAFETY GLASSES
̶ Wear safety glasses to protect from splashing cleanser and
flying parts
PROTECTIVE GLOVES
̶ Wear protective gloves to protect from sharp-edged objects.

Wear personal protective gear for the Protective Protective Protective Safety gog-
following activities. work footwear gloves gles
clothes

Machine transport. x x x
Setup the machine and connect it. x x
Maintenance work. x x x
Observe the manufacturer's documentation for the
individual components of the machine!

Version: 10.12.14 Page 22 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Protection Devices
Separative and non-separative protection device
Labelers without limitation of the tamp force to 50 Newton (s. page 17) require for operat-
ing an additional protection device (compare the supplied Assembly Instruction). Only by
using an additional protection measure, the Legi-Air 4050I HS (with High-Speed-
Applicator) will be a "complete machine" according to machinery directive 2006/42/EG.
If such a labeler is installed in a not-safeguarded area, additional protection measures are
required to prevent reaching upper limbs from dangerous areas. If the protective measure
is not supplied its design is the responsibility of the operator or user.
Example of an access protection measure (s. Fig. 2-4) according to the EN ISO 13857.
For the conceptual design of the protection measure, the elements of Safety of Machinery
2006/42/EC are to consider.

Fig. 2-4: Example of a Safety Guarding

System cover
The fixed and screwed system covers protect the user against mechanical hazards.

Version: 10.12.14 Page 23 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Emergency stop function

Labelers without limitation of the Tamp force to 50N (s. page 17) require as to the pneu-
matic powered movements and the resulting powers an additional safety measure and a
safety circuit for switching off the air pressure.
An integrated emergency stop relay (safety level 2-3, according to DIN EN ISO 13850) is
connected with the safety door switch (s. Fig. 2-5, 2) of the cabinet door. A relay contact
for scanning the operating status (s. air pressure monitor) can be used by the customer.

Turning off the air pressure

For turning on and off the air pressure supply, the labeler without limitation of the tamp
force to 50N provides a remote pushbutton box (s. Fig. 2-5, 1). The access door of the
protection device is controlled by a safety door switch (s. Fig. 2-5, 2). Remote pushbutton
box and safety door switch are each connected directly at the labeler by a feed line.

Fig. 2-5: Remote pushbutton box (1) and safety door switch (2)

No. Description
1 REMOTE PUSHBUTTON BOX

2 SAFETY DOOR SWITCH

Function of turning off the air pressure

If the door of the protective cabinet is opened or if the air pressure supply descends under
a required value or if the red [air pressure "OFF"]-switch of the remote button box is
pushed, the internal emergency stop relay switches off the valve for the air pressure sup-
ply and bleeds the systems. The labeler changes to failure "Emergency Stop", is immedi-
ately without power and pressure and thus not able to work (s. b. air pressure monitor).

Version: 10.12.14 Page 24 of 101 GB

Chapter 2 Safety Regulations 40001851 BTA Legi-Air 4050I

Turning on the air pressure

In order to switch the air pressure on with the green [air pressure "ON"] –switch with the
remote button box, following conditions have to be fulfilled:
¥ Door of the cabinet is closed (safety door switch)
¥ Required air pressure supply is available (min/max values can be adjusted by display
controller).
¥ The labeler is switched on.
¥ The black [Start] key of the remote button box was pushed once.

This reliably prevents the compressed air from switching on uncontrolled and automatical-
ly after a general failure of the air pressure or after opening the door of the cabinet.

Air pressure monitor

For observance of the operating status a potential-free relais output is available (X5:
clamp K11, K12) which is closed at active air pressure. A detailed diagram can be found
in spare part documentation with part number 21800548.

Working places operator personnel

The Legi-Air 4050I is an automated working print- and apply system and does not require
interventions during the labeling operation.
For labeler without limitation of tamp force to 50N, it is additionally valid:
When the labeling system is operating without any malfunction, the operator may
only be in the safe area, that is, the area covered by the protective measures.
Only one person is permitted to replace the labels and coloured ribbon when the labeling
system has stopped operation.
After troubleshooting and/or restarting the labeling station, the operator must im-
mediately leave the hazardous area and has to stay in the area designated by the
safety measures.
The operator’s side is generally the system’s front side (ref. Fig. 4-1 page 29 resp. Fig. 4-2
page 31).

Version: 10.12.14 Page 25 of 101 GB

Chapter 3 Technical Specifications 40001851 BTA Legi-Air 4050I

3. Technical Specifications
All information correspond to the standard serial machine of Legi-Air 4050I and may devi-
ate. Customer-specific values can be found in the approval drawing (please inquire if nee-
ded).

Dimensions (H x W x D in mm) *750 x 1050 x 860

Weight (without label roll) from 120kg

Power connection: 92-263 VAC / 50-60Hz (1~)

Power consumption: max. 580 W (incl. print engine)

Environmental tempera-
10- 35 ° C
ture:
Environmental conditions: 15-95 % relative humidity (non condensing)

Protection class: IP 20

Air pressure connection: 6 - 7 bar (according to DIN ISO 8573-1)

Air Pressure Quality according to DIN EN ISO 8573-1
- Residual Oil Content (Quality Class 5) = 25 mg/m³
- Residual Dust (Quality Class 3) = 5µm ; 5 mg/m³
- Residual Water (Quality Class 4) = 6 g/m³ ; +3 °C

Maximum air pressure Up to 200 Nl/min (under extreme conditions)

consumption: (0,3 - 3 liter per applying cycle)
* is valid for strokes until 300mm length. Otherwise tower construct in stroke area

Information on further dimensions

Maximum usable stroke

20 mm (up to optional 1160 mm)
length:
Tamp size (W x H): max. 150 x 210 mm / min. 10 x 5 mm

Label size (W x H): max. 150 x 210 mm / min. 10 x 5 mm

Label roll, outside diame-

Ø =300 mm (corresponds to 450 rm) core = 76 mm (3 “)
ter:

Performance data

Application rate Up to 100 labels/min. (depending on label size, stroke length…)

Applying distance 0 - 50 mm (depending on label size)

+/- 0,8 mm , with an applying distance less than 50% of the
Application accuracy smallest label side

Version: 10.12.14 Page 26 of 101 GB

Chapter 3 Technical Specifications 40001851 BTA Legi-Air 4050I

Information on operation

LCDisplay 2-lines with 20 digits each

(Background lighting)

Operator keys 5 buttons ([START], [STOP], [Enter], [>] and [<])

Noise level
The measurings in a distance of 1 meter to system surface and 1,60 meter above the floor
provided following noise levels:

A- Sound Pressure Level 72 dB

C- Sound Pressure Level 80 dB

Information on compatible print engine types

Possible print engine types that can be built in the Legi-Air 4050I:

Manufacturer Description / Print Width/ Print Resolution

Avery DPM 4 / 106 mm 300 dpi
DPM 5 / 127 mm 300 dpi
DPM 6 / 160 mm 300 dpi
CAB PX4 / 104 resp. 105,6 mm 200 / 300 / 600 dpi
PX5 / 104 resp. 108,4 mm 200 / 300 dpi
PX6 / 168 resp. 162 mm 200 / 300 dpi
Sato 8485Se / 112 mm 200 dpi
8490 Se / 112 mm 300 dpi
8485Se / 152 mm 200 dpi
Zebra ZE 500 / 104 mm 200 / 300 dpi
ZE 500 / 168 mm 200 / 300 dpi
110 Pax / 104 mm 200 / 300 / 600 dpi
170 Pax / 168 mm 200 / 300 / 600 dpi

Version: 10.12.14 Page 27 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

4. Description of the labeler

Function and application field of the labeler

Areas of application
The Legi-Air 4050I is used to label products automatically. The label contains customized
data (for instance: barcodes EAN128, date, time/date, logo…), which is printed topically
by an integrated printing engine.

Labeling positions
The labeling can be arranged at all sides (frontside and backside only with optional rotat-
ing tamp) depending on machine attitude onto the product without stopping the product.

Printing of the labels

The Legi-Air 4050I can be operated in combination with different print engines. In the
chapter “Technical Specifications” you will find an overview of all possible combinations.
For used print engine, the manual (Quick-Reference Guide) is enclosed in the scope of
supply.

Closed cabinet with pneumatic slide

The Legi-Air 4050I is located in a cabinet for a better protection against dust or low tempe-
ratures (with optional heating). The necessary tamp outlet in the cabinet’s floor is closed
during longer idle times (between the labelings) by a slide automatically whereby a more
efficient protection is realized.

Version: 10.12.14 Page 28 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

Complete overview Legi-Air 4050I

Figure: Legi-Air 4050I in righthand version (RH)

Fig. 4-1: Legi-Air 4050I RH in side view and Legi-Air 4050I RH in top view

No. Description
1 SYSTEM CABINET

2 LOW LABEL SENSOR (OPTIONAL)

3 UNWINDER DISC

4 DANCER ARM (UNWINDER)

5 REWINDER MANDREL

6 DANCER ARM (REWINDER)

7 PRINT ENGINE

8 AIR ASSIST

9 TAMP

10 LINEAR THRUSTER

11 ROTARY SWITCH (OPEN/CLOSE SLIDE)

Version: 10.12.14 Page 29 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

No. Description
12 HMI-OPERATOR TERMINAL

13 PROTECTIVE TUBE FOR GUIDING RODS

14 SIDE HINGE (OPTIONAL)

15 U-ARM (OPTIONAL)

SAFETY DOOR SWITCH (ONLY LEGI-AIR 4050I WITHOUT LIMITATION OF THE

16
TAMP FORCE)
REMOTE BUTTON BOX (ONLY LEGI-AIR 4050I WITHOUT LIMITATION OF THE
17
TAMP FORCE)
18 CYLINDER (LINEAR STROKE)

19 CYLINDER (SLIDE)

20 TAMP OUTLET

21 RE-/ UNWINDER COVER

Version: 10.12.14 Page 30 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

Figure: Legi-Air 4050I-versions in different installation positions (RH/LH)

Fig. 4-2:Examples Legi-Air 4050I in different installation positions (RH/LH)

Version: 10.12.14 Page 31 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

Figure: Legi-Air 4050I side views (LH/RH)

Fig. 4-3: Legi-Air 4050I RH and LH in side views

No. Description
1 SYSTEM CABINET

2 LINEAR THRUSTER (APPLICATOR)

3 TAMP PAD

4 AIR ASSIST TUBE

5 SLIDE (TAMP OUTLET)

6 REWINDER 3-INCH COLLAR

7 U-ARM (OPTION)

8 UNWINDER

Version: 10.12.14 Page 32 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

Figure: Legi-Air 4050I rear side (RH / LH)

Fig. 4-4: Legi-Air 4050I (RH/LH) rear side

No. Description
1 LEGI-AIR 4050I CABINET‘S REAR SIDE

2 APPLICATOR CONNECTIONS (SENSORS, POWER…)

3 CABLE FEEDTHROUGH (PRINTER DATA CABLE, APPLICATOR CABLE…)

4 SIDE HINGES (OPTIONAL)

5 COMPRESSED AIR CONNECTION (KS4-CK) + DRAIN VALVE

Version: 10.12.14 Page 33 of 101 GB

Chapter 4 Description of the labeler 40001851 BTA Legi-Air 4050I

Application modes
The Legi-Air 4050I applies the labels onto stopped or moved products. When the printing
procedure starts, the pneumatic slide in the floor of the system cover is opened. Therefore
several application procedures (modes) are possible and can be configured by the dis-
play.

Tamp-Blow-Mode
The printed label is extended before application on a vacuum tamp to product proximity
and it is then blown off onto the product.
The Tamp-Blow-Mode is often used as the products need to be labeled contactless and it
thus presents a low-wear working method.

Tamp-On-Mode
In difference to Tamp-Blow-Mode, the product is touched during labeling. The label is
pushed onto the stopped product by the vacuum tamp. This mode requires a change of
the applicator configuration and resp. an adjustment of the labeling position.

As soon as the tamp- resp. vacuum tamp is in home position at print engine, the slide is
closed after a certain configured time has expired. If a new print is started within this time,
the slide remains open.

Management of printing data

Printing data sent to the labeler have to be available in different versions depending on
requirement:

Batch operation (Batch processing)

Herewith a print order for a larger number of identical labels is fowarded to the print en-
gine. All products receive labels with identical printing data.

On-demand operation (Single processing)

Synchronized with the transportation of the products, the Legi-Air 4050I receives a data
file of one label before the product arrives. If the product should receive a labeling on two
sides (special applicator required), the second label is generated automatically by the Re-
print-Function of the printer. The advantage is that there is no difference between a two-
side labeling and a simple labeling (front- or side labeling) from the point of print data edit-
ing. At a two-side labeling you can thus avoid effectively that one product receives two la-
bels with different printing data by fault.
A wrongly transmitted print order or a data file that should not be used after a failure can
be deleted by a software command. This deletion command has to be sent before the
transmission of the next order by the data interface.

Version: 10.12.14 Page 34 of 101 GB

Chapter 5 Transport 40001851 BTA Legi-Air 4050I

5. Transport
Delivery
If the labeler is delivered by a carrier, check the packaging for damages. If anything is pe-
culiar, we kindly ask you to claim at the carrier and mark it on the delivery note.
Scope of delivery
The scope of delivery of the Legi-Air 4050I depends on the ordered options and the cus-
tomer’s application. Please control the scope of delivery when receiving the systems on
the basis of the delivery note.

Transport and unpackaging

Safety regulations

Hazard from lifted loads.

Falling loads can cause severe injury or death.

̶ Do not walk under a lifted load. The load may not be tilted.
̶ The location of the center of gravity must be taken into account
when transporting the system.

Hazard from tight straps.

The straps are secured tightly and can snap off if they are cut and
cause severe injury.

̶ Wear protective glasses and gloves

̶ Stand to the side outside of the hazard zone

Hazard from falling parts.

̶ Wear protective footwear.

Remove the packaging material and the transport securing devic-

es only at the site of use, and transport the labeling system in its
original packaging to the labeling site. If the labeling system is not
secured, it can tip over easily when transported.

Requirements
¥ The labeling system is packed when delivered (with possible exceptions), that is
¥ It is standing on a pallet
¥ It may be wrapped with stretch film

Version: 10.12.14 Page 35 of 101 GB

Chapter 5 Transport 40001851 BTA Legi-Air 4050I

¥ (only with protective cabinet)

¥ It may be secured with additional straps and the rubber feet may be screwed to the
pallet
Required equipment
¥ Suitable means transport (double pallet trucks or forklifts…) with sufficient load
(weight information see chapter Technical Specifications). When using forklift, drive
slowly.
¥ (Only with protective cabinet) For unloading the system from pallet, a double hand
fork lift truck or pallet jack or…
¥ 2-3 persons, who have to wear safety shoes
¥ Stable support for the labeler (without protective cabinet)
¥ Use a safety steel strapping cutter to remove the straps
¥ Wrench for transport securing screws

Fig. 5-1: Packaging examples

Pos. Description
A PACKAGING EXAMPLE: LEGI-AIR 4050I

B PACKAGING EXAMPLE: SWITCH CABINET

1 STRETCH FILM

2 PALLET

3 TRANSPORT SECURING SCREW

4 RUBBER FEET

5 STRAP

Version: 10.12.14 Page 36 of 101 GB

Chapter 5 Transport 40001851 BTA Legi-Air 4050I

Instruction
Use the following procedure to transport the labeling system to its site of use.

Step Procedure
1 Transport the labeling system to its site of use (within 3 m). The labeling
system is precisely positioned during installation by a Technician from the
Bluhm Weber Group.
The straps are secured tightly and can fly back when they are cut and cause
injury.

2 Remove any film and straps (if available). Legi-Air 4050I

3 Open the package and remove the packaging and filling material.

4 Lift the system with at least 2 persons from the packaging and put it onto a
stable base.

5 Before setup, remove all transport securing devices.

Storage conditions
The conditions for storing a labeling system are the same as those of normal operation.
For details see the chapter: "Technical Specifications”.

Instruction
Store the labeling system securely as follows.

Step Procedure
1 Remove the label material and the *²ribbon from the system.
2 Fix the labeler onto pallet(s) and transport the system to its storage location.
For securing and transporting the labeling system, follow the safety instruc-
tions in the above section "Transport and unpackaging".
3 To protect from dust, cover the labeling system with a cotton or paper cloth.
To prevent the formation of condensate, do not use film.
4 Climatize the storage locations as indicated in chapter „Technical Specifica-
tions“.
5 Before restarting the labeling system, check the system.

Version: 10.12.14 Page 37 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

6. Installation and initial startup

Safety regulations
Hazard from direct or indirect contact with voltage-
conducting parts.

DANGER TO LIFE!
When individuals touch parts that conduct electricity arising from
malfunctions.
̶ Only electricians may work on the switch cabinet and electri-
cal equipment.
̶ Regularly check the electrical equipment of the labeler (see
the chapter: "Maintenance/Service").
̶ Immediately take care of loose connections and damaged
cables.
̶ Always keep the switch cabinet locked.
̶ Before working on electrical equipment, switch the miniature
circuit breaker to "0" position and secure it against being ac-
cidentally turned on. If possible, disconnect the power.

Hazard from easily flammable label material.

FIRE HAZARD!
The ribbon and labels are easily flammable. Potential injury from
fire and smoke.
̶ Keep away from sources of ignition and open fire

Hazard from moved assembly parts.

RISK OF INJURY!
Entanglement- and crushing hazard due to pneumatically or mo-
tor-driven assembly parts of the labeler.
Motion sequences or rotations start in labeling operation sud-
denly and abruptly.
̶ Do not grip in, at or between the moving parts

Version: 10.12.14 Page 38 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Hazard from residual force in pneumatic components.

RISK OF INJURY!
Whipping compressed air hoses, thrown parts or uncontrolled
moving parts can cause injury.
̶ Before connecting the compressed air, check to ensure that
all pneumatic connections are correctly seated and secure if
necessary.
̶ The pneumatic system awaiting maintenance must be bled
before any of the pneumatic components can be removed.

Tripping hazard from connecting lines.

RISK OF INJURY!
Connecting lines for power, compressed air and computer and
signal lines can pose a tripping hazard, causing serious injury.
̶ Release the tension of connecting lines to the system and run
them so that they do not pose a hazard.

Danger of injury from corners and edges.

RISK OF INJURY!
Scrapes and cuts can result from sharp edges and pointed cor-
ners. Always keep the work area clean. The label web has sharp
edges.
̶ Observe caution when working close to sharp edges and
pointed corners. Remove unnecessary objects.
̶ In case of doubt, wear protective gloves.

Version: 10.12.14 Page 39 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Installation
Continuous operation with minimal wear and downtime can only be ensured when the
system is installed properly. Fine adjustments to the conditions of use are essential when
installing the system. These fine adjustments are adapted to the surrounding conditions.
To make these fine adjustments, detailed professional knowledge is necessary that arises
from experience with labeling systems.
This required professional knowledge cannot be completely communicated by the operat-
ing instructions; therefore a Technician from the Bluhm Weber Group needs to perform
the installation or accept the labeling system in a final inspection. The warranty does not
cover damage or consequential damage arising from improper installation lacking the
necessary fine adjustments.

Requirements to the installation site

¥ An enclosed and clean room.
¥ Flat, solid base, any unevenness may not exceed 5 mm when stands from the Bluhm
Weber Group are used.
¥ Sufficient bearing capacity: 1,500 kg/m².
¥ Low vibration environment.
¥ Sufficient lighting: 500 Lx.
¥ No direct exposure to sunlight or a radiator.
¥ The machine may not be operated within electrostatic or magnetic fields. This can
cause the controls to malfunction.
¥ A proper energy supply (electricity and compressed air) according to the chapter,
"Technical Specifications" on page 26.

Placing the labeling system

¥ The labeler may not contact the product when the applicator is retracted (in home
position at peeler bar).
¥ The swung out resp. extended applicator has to stand possibly parallel to product
surface. It may not touch the surface depending on application modi (s. page 34)
(distance 10-50 mm).
¥ The installed position must allow sufficient access for users and service technicians.
In particular at all times, the mains switch / plug must be freely accessible to discon-
nect the power supply
¥ Make sure that all fasteners are sufficiently tight.
¥ Observe all of the items under "Intended use" in the chapter “Safety Regulations”.

Version: 10.12.14 Page 40 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Setting up the labeling system

System installation at a stand of the Bluhm Weber Group!
If the system is installed at a stand of the Bluhm Weber Group, please follow the instruc-
tions of supplied stand documentation.

Requirements
¥ The labeler is completely installed (in protective cabinet or at stand > s. hint above).
¥ The labeling system is unpacked and prepared (see the chapter: "Transport" on
page 35) near the labeling site.
¥ The connections for the compressed air and electricity are close to the labeling site
(maximum distance of 1.5 m) as specified in the chapter: "Technical Specifications“
¥ The base is solid, level and flat

Required equipment
¥ Screw wrench (for rubber feet adjustment)
¥ Air lever

Instruction
Set a labeling system up as follows.

Step Procedure
1 Move the labeling system to labeling site (where the label should be applied
onto the product). Move labelers without rolls piece by piece diagonally.
Consider all points for "Placing the labeling system" on page 40.

2 Adjust the labeling system with an air lever by the adjustable feet horizontal-
ly. (With rolls, the brakes have to be locked).

Connecting the labeling station

The labeling station requires electricity to work. For details see the chapter: "Technical
Specifications".

Version: 10.12.14 Page 41 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Overview of the connections at the labeler

The connections of the labeler are at the re-/unwinder cover at the rear side of the labeler
in the area of the label re- and unwinder. Please find the explanation of the single connec-
tions that are shown in Fig. 6-1 as follows.

Fig. 6-1: Electrical connections at the Re-/Unwinder cover at the rear side

No. Description
1 IEC625- CONNECTION WITH FUSE

2 DISPLAY

3 LOW LABEL PREWARNING

4 SECONDARY PRODUCT SENSOR

5 PRIMARY PRODUCT SENSOR

6 ALARM LAMP

7 IEC625-CONNECTION FOR PRINT ENGINE

8 NET SWITCH (POWER ON/OFF)

9 USB

10 SIGNAL

11 APPLICATOR

12 PRINT ENGINE INTERFACE

Version: 10.12.14 Page 42 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Connection to supply voltage

Requirements
¥ Power supply according to "Technical Specifications" is installed close (max. 1,5 m
away) to the labeling site
¥ Power switch is OFF (in "0"-position)
¥ Power voltage cable and net connection cable (s. in accessories box)

Instruction
The labeler is connected to supply voltage as follows.

Step Procedure
1 Plug the power voltage cable that is not yet connected to the IEC – connec-
tion of the system.
2 Connect the print engine by the net connection cable with the labeler (Pos. 7
Fig. 6-1, page 42).
3 Connect the power voltage cable with the 230 Volt supply voltage.
Entanglement hazard at label liner rewinder! After turning on, the rewinder is
activated for a few seconds.
- Maintain a distance from rewinder!

Version: 10.12.14 Page 43 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Connection to compressed air

Please find the compressed air connection at Fig. 4-4 page 33
Requirements
¥ Compressed air supply (KS4-CK-6 coupling) according to "Technical Specifications"
is next to the labeling site (max. 1.5 m distant).
¥ Service fittings, connecting line with a KS4-CK-6 coupling jack and pneumatic hose
(see the accessories box)
¥ The filter-regulator-manometer combination is intalled in upright position (drain valve
at bottom side)

Instruction
Connect the labeler to the compressed air as follows: The instructions refer to Fig. 6-2

Step Procedure
1 Ascertain that the slide valve is in OFF position (ref. Fig. 6-2 >> slide at bot-
tom side = ON position !!).

2 Connect the labeler with the maintenance unit by the connection (4) with the
supplied pneumatic tube. Control the connection if it is fixed (the tube may
not be peeled off).

3 Connect the coupling jack (3) with the connection coupling of the air pres-
sure supply

4 To turn on the compressed air, please pull the shutter to ON-position

(above). If adjustments of the compressed air should become necessary,
please see steps 5-7.

5 Pull out the button (1) of the regulator.

6 Adjust the compressed air to desired value (standard value 5bar). Turn
therefore the button counter clockwise (arrow direction "+") to increase the
input pressure resp. In clockwise direction (arrow direction "-") to reduce the
input pressure.

7 Push down the button (1) of the regulator for interlock.

No. Description
1 REGULATOR-BUTTON

2 SHUTTER VAVLE (IN ON-POSITION)

3 COUPLING PLUG

4 CONNECTION FITTING (TO LABELER)

5 COMPRESSED AIR MANOMETER

6 COLLECTION BOWL

7 DRAIN VALVE

Fig. 6-2: Filter-Regler-Manometer-

Combination

Version: 10.12.14 Page 44 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Connection and positioning of the product sensor

The product sensor inputs are parallel with the trigger inputs of
the I/O interface (e.g. coming from the conveying system) con-
nected. In order to avoid damages at the electronics, inputs may
never be used together.

For connection of sensors that are not included in the scope of

supply, an extensive expert knowledge is required and this may
only be arranged by qualified experts.

The trigger signal for a labeling has to be forwarded from a product sensor (option) or by a
potentialfree contact of the conveying system (CS) to the labeler (ref. page 48).
The M12-industry-connection jacks are at the rear side of the re-/unwinder cover. They
are marked with "Product Sensor P" (primary) and "Product Sensor S" (secondary). Both
sensor inputs may be configured by the display. To trigger print procedure, applicator
movement or blow-off procedure separately, several signals and thus sensors or signals
of the conveying system are required.
The mounting of the sensor and the reflectors (if available) has to allow a subsequent
change of the position.

Requirements
¥ No transportation of products
¥ Sample product
¥ Power supply is OFF (in "0"-position)

Instruction
Please position the product sensor as follows.

Step Procedure
1 Connect the sensor/s to labeler (plug in and screw together).

2 Place the product so that the extending tamp would apply the label to de-
sired position onto the product.

3 Place now the product sensor to the front resp. rear edge of the product.

Labeling without product stop

The tamp extension time has to be calculated also for the sensor position,
whereby the light barrier (in running direction) has to be positioned in ad-
vance.

4 If the labeling cycle is triggered separately, the second sensor has to be

positioned early in advance that time passes until the product reaches the
next sensor that is sufficiently for the cycle to be triggered (e.g. printing).

Version: 10.12.14 Page 45 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

"Display" -connection
This connector is one of five industrial standard connectors (M12, female) located on the
Re-/Unwinder cover at the system’s rear (ref. Fig. 6-1, page 42). The "display" jack is pro-
vided to connect the display controller only. An optional cable set (5 m) enables to change
installation position of the display.

"Low label sensor" -connection

The connection (ref. Fig. 6-1, page 42) with description "Low label sensor" belongs to the
option "Low label warning". If this option is connected, it is ready for use. If this option is
not installed a terminating plug (s. spare part manual) should be connected at "Low label
sensor" connection

Low label warning (Low label)

By means of the reflective sensor (s. Fig.

6-3) the label roll is scanned. A signal is
fowarded (s. a.), if the label roll under-
runs a diameter of 98mm (+/- 3mm).
In connection with the 3-colored alarm
option the signal is shown by the yellow
lamp. Additionally the signal is provided
potentialfree for evaluation of the cus-
tomer at the I/O signal interface (s. page
48).

1 = REFLECTIVE LIGHT SENSOR Fig. 6-3: Sensor for Low Label Warning (Option)

"USB" - interface
The Legi-Air 4050I provides an USB interface (ref. Fig. 6-1, page 42) that enables an up-
load of the Firmware (comparable with an operating system) of the applicator controller.
Therefore, amongst the firmware-file a particular program is required.
A backup feature via USB is already available to archive the individual menu settings.

"Applicator" -connection
The 9-pin female connector located at the re-/unwinder cover’s rear (ref. Fig. 6-1, page
42) serves for connection of the applicator (tamp unit). This interface connects voltage
supply as well as all signals from co-processor to trigger the pneumatic valves and the
testing equipment.

Version: 10.12.14 Page 46 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

"Alarm lamp" -connection

Limited power consumption.

Use only alarm lamp with LED-technique (2270995).

At overcharge an overheat control turns off CPU and auxiliary power as long as the
temperature is not decreased to a safe range.

For connection (ref. Fig. 6-1, page 42) of an optional alarm lamp
nothing else beside the light is required.
Please note the warnings with the appropriate meanings as fol-
lows.

Fig. 6-4: Alarm lamp

Light Meaning
Green appears when the machine is in operating mode (READY-Signal is true).

Yellow appears when “Low Label” or "Low Ribbon" is detected.

Red appears when the machine is in error condition (READY-Signal is reset). Pos-
sible causes: ribbon end or low label or applicator failure.

"Printer" -connection
The labeler is connected with the digital in-/output interface of the print engine by this
connection (ref. Fig. 6-1, page 42). Depending on print module type (s. "Technical Speci-
fications") a specific adaption cable is used.

Print engine setup (Printer)

The print engine is configured for use in the labeler before delivery. Setup details are doc-
umented in a system checklist and are a part of the supplied documentation folder.
Information on handling for the used print engine are to be found in the user manual which
is also included in the scope of supply.

Version: 10.12.14 Page 47 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

"Interface" (I/O-User interface)

This I/O interface (with description Interface ref. Fig. 6-1, page 42) is used to build a safe
connection between the conveyor PLC and the labeler. The jack is implemented as a 25-
pin female socket and can be connected directly or by using a Spring-Type Terminal Box.

Please find as follows a brief summary of all technical specifications of the I/O signal inter-
face as well as explanations of the functions and remarks for the assignment plans.

Inputs (I): Outputs (O):

Photo-MOS Semi-conductor relay, bipolar (any
Optocoupler bipolar (any polarity)
polarity)
Changeover relay (ALARM/READY)
Galvanically separated
N.O. / N.C. / COM
Input power 20 up to 30 VDC Shutter, unipolar
Signal inversion for selection ("active high" Capacity: Imax = 200 mA,
or "active low" by display) Switching voltage Umax = 40 VDC
Galvanically separated

(I) INPUT; (O) OUTPUT

+ 24 V
Label on tamp/COM (O)
SYNC/ N.O. (O)
Data Ready/ COM (O)
Home Position / N.O. (O)
Home Position / COM (O)
SYNC/ COM (O)
Trigger 1 "Apply" (I)
Print Signal / N. O. (O)
Print Signal / COM (O)
+ 5V (of print engine pin 2)
Trigger 3 "AUX" (I)
free
free
READY/ALARM / N.C. (O)
Reprint (I)
READY/ALARM / N.O. (O)
READY/ALARM COM (O)
Label on tamp /N.O. (O)
Trigger 2 "Print" (I)
Prewarning / N.O. (O)
Prewarning / COM (O)
Data Ready/ N.O. (O)
COM Input (I)
GND

Fig. 6-5: I/O- Signal interface (female / view from outside)

Version: 10.12.14 Page 48 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Inputs Function
For transmitter supply the system-specific 24VDC-power at Pin 1, 13 is
+24V / GND available. Capacity: max. 200 mA (with overcurrent protection).
Internal auxiliary supply by pin 2 of the 15 pin. Sub-D-connection of the print
5V engine.
Triggering of application procedure according to standard configuration. Per
Trigger 1 display-controller any trigger input (ref. pages 69, 72 and 76) can be as-
"Apply" signed.69
Triggering of printing procedure according to standard configuration. Per
Trigger 2 display-controller any trigger input (ref. pages 69, 72 and 76) can be as-
"Print" signed.

Trigger 3 Triggering of a function that was configured by display.

Instructs the machine to print the previously printed label without requiring a
Reprint new print order (data) (only with print engines from Pax II and Sato Se on).

Connection examples:
Customer’s side passive, supplies 24V from Legi-Air 4050I

Pin 1 Pin 1

Pin 23 COM Input Pin 25

Pin 17
Inp. Inp.
LA4050I Customer’s side
2 1
Inp. Inp.
LA4050I Customer’s side
2 1
Pin 17
COM Input Pin 25 Pin 23

Pin 13 Pin 13

Customer’s side active, supplies 24V, Common GND

Pin 23 COM Input Pin 25

Pin 17
Inp. Inp.
1 LA4050I Customer’s side
2
Inp. Inp.
LA4050I Customer’s side Pin 17
2 1

COM Input Pin 25 Pin 23

Fig. 6-6: Connection examples for separate resp. Common triggering of printing and applying

Version: 10.12.14 Page 49 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Outputs Function
General failure: output of READY/ALARM-Relais. The signal is active
(READY = N.O.; ALARM = N.C.), if following points are fulfilled:
- Operating state of the printer, independent from possible existing
READY / print jobs.
ALARM - Printer is not in Stop status (PAX).
- Labels and ribbon are available.
- Operating pressure is in defined print range.
- Labeler is available to label (not in stand-by, no error message)

Home Positi- Signal active if the tamp is in home position. (The system has to be switched
on on therefore).

Print Signal Signal is inverted thus inactive during printing or during label feed

Signal active, at low ribbon warning of the printer and additionally as an op-
Prewarning tion at low label warning (low label sensor required).
Inspection of availability of a label on tamp pad (by vacuum measuring).
Label on
The signal is active when the label lies on tamp pad. It is evaluated from
tamp Legi-Air 4050I and generates an error message in case of a failure.
The SYNC-output can be configured by a display controller and forwards a
SYNC pulse after or during the labeling cycle.
Signal is forwarded by Pin 14 of the 15 pin. Sub-D-connection of the print
Data Ready engine and signalizes stand-by for printing after the required printing data
have been transmitted completely.

Connection example:
Legi-Air 4050I Customer’s side

Pin 22

Output 1 Pin 16

Pin 18

Pin 5
PLC In "PRINT"
Output 3
Pin 3
PLC In "HOME"
Output 2
Pin 9
PLC In "READY"
Pin 8 PLC In " ALARM"

Fig. 6-7: Connection Examples for PLC-Inputs of the Customer

Version: 10.12.14 Page 50 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Label and ribbon loading

Refer to your specific print engine manual for more information on loading the
printer with ribbon (User manual or Quick Reference manual).

Ribbon loading
Requirements
¥ Suitable ribbon with inside or outside coating (IC / OC) according to printer specifica-
tion
¥ Ribbon width complies with or is more than label width

Instruction
The ribbon will be loaded in the print engine as follows.

Step Procedure
1 Open the print engine’s cover.
2 Refer to your specific print engine manual for the ribbon loading procedure.
You will find a loading diagram for ribbon and paper guiding inside the print
engine’s cover.

Label loading
Consider label roll version!
The Legi-Air 4050I only provides (without additional option) the use of label rolls with out-
side winding , i.e. with the view on the roll the labels adhering at outside of the label liner
(s. Fig. 6-8, examples 5 - 8). Only thus the function of the roll brake is ensured.

BE = LABEL WIDTH
BT = BACKING WIDTH
HE = LABEL HEIGHT
DK = DIAMETER CORE
DR = DIAMETER ROLL
A = GAP

Fig. 6-8: Label execution

Requirements
¥ The labels stick at the label roll at the outer side of the label liner (s. Fig. 6-8, examp-
les 5 - 8).

Version: 10.12.14 Page 51 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Instruction
The labels will be loaded in the labeler as follows.

Step Procedure
1 Open the door of the cabinet.

2 Rotate the outer unwind disk to align the set screw with the flat on the un-
wind mandrel. Remove the outer unwind disk from the unwind mandrel.
3 Load the label roll (with outside winding) onto the adapter ring (round alu-
minium ring with Ø = 76mm) of the inner unwind disc and up against the
inner unwind disc. The label roll must be oriented so that the material passes
through the print head with the label side at the top.
Put the unwinder disc again to the unwinder axis and lock it by screwing.
4 Remove all labels at the first 90 cm of the label web.
5 Guide the label material according to the images (Fig. 6-9 ff) through the
machine.

Fig. 6-9: LA 4050-I RH and LA 4050-I LH

6 Guide the paper within the print engine according the printer manual (nor-
mally you will find a label with the loading diagram inside the print engine at
the cover).
Please observe that the air assist tube is not by mistake covered by the
label web.
7 Before the backing paper can be fixed at the unwinder, the web only has to
be guided around the last free deflection roller of the dancer arm.
Wrap the backing paper onto an empty core or directly onto the rewinder
axis by means of the hook.
8 Turn the rewinder axis as long as the backing paper is pulled straight be-
tween drive unit and rewinder (possibly 2-3 wraps).

9 Make sure that the label material moves in a straight line from the inner un-
wind disc through the printer. Close the cabinet.

Version: 10.12.14 Page 52 of 101 GB

Chapter 6 Installation and initial startup 40001851 BTA Legi-Air 4050I

Initial operation
Safety regulations

Danger caused by actively triggered movements.

DANGER OF BEING CRUSHED!

The movements of the applicator are driven by a pneumatic cylin-
der.
̶ Maintain a distance from applicator.

Requirements
¥ Knowledge about product transport
¥ One or more sample products
¥ Print media (labels, ribbon if necessary) are loaded correctly (s. page 51)
¥ Labeler is connected to power and compressed air
¥ Print data can be sent to print engine
¥ Triggering of labeling is possible by product sensor or I/O interface

Instruction
Please put the labeler into operation as follows..
Procedure with Legi-Air 4050I
Step
…
…with Safety Guardings … without Safety Guardings
1 Place product on conveying system -

2 Turn on the labeler at print engine. (see also "Turn on and off labeler" in
chapter "Operation").

3 Leave the dangerous zone and go

-
behind the safety guardings.

4 Close the door of the safety guard-

-
ings (safety door switch).

5 Press the green [Pressure "ON"]

button of the remote button box, to -
switch-on compressed air.

Crushing hazard! Maintain a distance from tamp

4 4
6 * Push black [Start]-buttons at remo- * Push [Start]-button at display to
te button box to start labeling opera- start labeling operation.
tion.
Depending on adjusted system configuration (s. system-check list) the Legi-
Air 4050I starts the printing procedure when the data transfer was comple-
ted.

8 Send print data to printer.

9 Turn on conveying system to feed product.

4
* Presumed the start procedure of the printer is terminated and no further failures are existent.

Version: 10.12.14 Page 53 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

7. Operation
Operation of the labeler
Safety instruction

Hazard from moved assembly parts.

RISK OF INJURY!
Entanglement- and crushing hazard due to pneumatically or mo-
tor-driven assembly parts of the labeler.
Motion sequences or rotations start in labeling operation sud-
denly and abruptly.
̶ Do not grip in, at or between the moving parts.

The Legi-Air 4050I is an automatically working labeling system requiring no manual

interventions after starting the labeling operation.

Opening and closing the cabinet’s door

The cabinet’s door provides an interlocking system that is
normally used in switch cabinet construction.
The example in Fig. 7-1 shows how to open the door. For clo-
sing, please keep both doors closed and move lever (3) to
home position.

If the version differs, please observe the supplied instruction of

the manufacturer.

Opening the door will not cause a shut-off of the la-

beler!

Please observe the safety instruction (s.a.)!

Fig. 7-1: Example for door latch

Version: 10.12.14 Page 54 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Temperature setting for swich cabinet heatings (Option)

Hazard due to hot surface.

RISK OF INJURY!
Hot surfaces may cause severe burns.
̶ Avoid touching of hot surfaces.
̶ No flammable objects may be located near hot surfaces.

Faults due to incorrect temperature settings.

Too high or too low temperatures may have a negative impact
on the label’s peel off behaviour.
̶ Observe the specifications of the used labels (if necessary
please inquire at manufacturer).
̶ Observe also the temperature range of the labeler (s. chapter
„Technical Specifications“)

If the use of the labeler is also required at low ambient temperatures, an optional heating
is necessary.
Significantly for the temperature setting is beyond the valid temperature range of the labe-
ler, (s. chapter „Technical Specifications“), the specification of the used label material. As
the peel-off behavior of the labels depends on the temperature. Too low or too hight tem-
peratures may avoid that the label peels off from liner.

Fig. 7-2: Example of a switch cabinet heating

No. Description
1 THERMOSTAT

2 TEMPERATURE SETTING

3 HEATING

Version: 10.12.14 Page 55 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Requirements
¥ Coin or screwdriver.

Instructions
Please set the temperature within the cabinet as follows.

Step Procedure
1 Open the cabinet’s door.

2 Turn the setscrew of the thermostat to the required temperature (according

*8 label specification).

*8 Label material that is outside the temperature range of the labeler (s. Technical Specifications), can not be applied with
the Legi-Air 4050I. (Please contact your label material supplier with regard to an alternative material).

Version: 10.12.14 Page 56 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Manual operation of pneumatic slide

Hazard from moved assembly parts.

RISK OF INJURY!
Entanglement- and crushing hazard due to pneumatically or mo-
tor-driven assembly parts of the labeler.
Motion sequences or rotations start in labeling operation sud-
denly and abruptly.
̶ Do not grip in, at or between the moving parts.

The rotary switch for manual

opening of the slide that is
placed in the housing’s bot-
tom, is located at the hou-
sing’s rear side (presumed
that compressed air and ener-
gy are available).

In automatic operation („0“-

position) the slide is triggered
by the labeler. It opens as
soon as the labeler starts prin- Fig. 7-3: Slide control
ting the label.
As soon as the tamp is in home position at print engine, the slide is closed automatically
after a certain time has elapsed. If a new print should be started within the time, the slide
remains open.
¥ Position„0“ = automatic
¥ Position „I“ = open (Observe the safety instruction (s.a.)!)

Turn on and off labeler

For operation of the Legi-Air 4050I the power switchs of labeler and print engine have to
be turned on. The labeler checks the status of the print engine during switching on the
supply voltage (by print engine interface). This function enables to switch on and off the
labeler by one (preferred by you) power supply. This is particularly advantageous if the
access to the labeler is limited in any way.
If the print engine remains generally turned on, you are able to switch on and off
the labeler together with the power supply of the Legi-Air 4050I.

When turning on the labeler, the message "press <START>" appears in display, so that
the labeling operation is only enabled after pressing the [Start]-button (Details s. instruc-
tion below).
A certain parameterization (Programming 007) enables to initialize an automatic*4 start. I.
e. after am adjusted waiting period (between 001-254 seconds or directly) the labeler acti-
vates independently the labeling operation.

Version: 10.12.14 Page 57 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Start labeling operation

Requirements
¥ The initial operation (s. chapter "Installation and initial startup") was terminated suc-
cessfully.
¥ Labeler is supplied with compressed air, power, if applicable labels and foils.

Instruction
Please start the labeling operation as follows.
Procedure with Legi-Air 4050I
Step
…
…with Safety Guardings … without Safety Guardings
1 Turn on the labeler (for details refer
to the above section), leave the Turn on the labeler (for details refer
danger zone and go behind the safe- to the above section).
ty guardings.

2 Close the door of the safety guard-

-
ing (safety door switch)

3 Press the green [Pressure "ON"] After turning on, the labeler goes into
button of the remote button box, to the idle mode and the following text
switch-on compressed air. message appears in the display::
After turning on, the labeler goes into
the idle mode and the following text
message appears in the display::

[Link] 7BB0
Press <START>
XX stands for the version number of the firmware installed in the controller.

After a few seconds the first line changes and information on system are
provided one after another.
4 4
4 * Press the black [Start] button of * Press the [Start] button of the dis-
remote button box, to enable the play, to enable the labeling opera-
labeling operation. tion.
4
* Assuming the boot procedure of the print module is terminated and no further failures exist.

Version: 10.12.14 Page 58 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Stop labeling operation

Instruction
Please stop the labeling operation as follows
Step Procedure with Legi-Air 4050I
…with Safety Guardings … without Safety Guardings
1 Pushing of the red [Air Pressure
Pressing the [Stop] key twice stops
OFF] key stops the labeling opera-
the labeling operation
tion

2 Turning off resp. the labeler at the print engine or at the power supply of the
labeler (s.a.)

3 Consider the instructions "Putting the system out of service" (page 59 ff).

Putting the system out of service

When turning off the system for several hours, the label web
must be removed from the applicator.

The label material running around the deflection rollers is curved which can cause prob-
lems with the operation mode. This characteristic of the labels as well as the retained cur-
vature depend on the material which can vary significantly between the different print me-
dia. The ambient conditions such as high temperatures and humidity enhance this effect.

When opening the print engine’s cover, the labeler changes to failure. Turn off the com-
plete labeler by the net switch.

Remove critical label material before long breaks and after end of work from la-
beler!

Version: 10.12.14 Page 59 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Operation of the display-controller

The display controller consists of a large LC-Display and
5 buttons as well as 2 status LEDs. It comprises a con-
nection cable with a 5-pin M12 industry plug and it is
connected at the backside of the labeler (ref. Fig. 6-1,
page 42).
The installation position can be freely chosen and
should, if not above the print engine, be at a well acces-
sible position close to the labeler. The display is available Fig. 7-4: Display
with different cable lengths.

Functions of the operator buttons

The [Start]-button serves for starting *5 the labeler. With pressing the
button the labeling operation is activated and an error message (if shown)
is acknowledged.
The [Stop]-button serves for ending the labeling operation. After pushing
the button, the labeler changes to "Stand-by". (Only) now it is possible to
call up a menu of the controller. Anew pushing of [Stop] sets the labeler
in idle mode like after switching on. An error message (if shown) is
acknowledged.

Crushing hazard due to moving assembly parts! *5

At Programmiung 007 to „automatic start“ (value 001 to
254) the tamp moves at second pushing of [Stop]-button af-
ter parameterized time automatically back to home positi-
on“.
- Do not grip in, at or between moved parts.

Crushing hazard due to moving assembly parts! *5

Also without printed label an application cycle can be trig-
gered by the JOG-Function.
- Do not grip in, at or between moved parts.
The [Enter]-button has 3 functions:
a) JOG-function*5: during labeling operation the Legi-Air 4050I can be
triggered by this button.
b) In combination with further buttons for calling up menus.
c) In the menus, the [Enter] button serves for changing a parameter or
to confirm inputs.
The buttons [] / [] have respectively 3 functions:
a) In combination with further buttons for calling up menus.
b) For navigation in menus.
c) For changing parameter values ([] = decreases/ [] = increases).
The autorepeat-function of the buttons allows for a fast change of high
values if the corresponding button is kept pushed.
5
* Is only valid for labelers with protective cabinet when the safety door switch is closed.

Version: 10.12.14 Page 60 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Status-LEDs
Above the buttons [Start] and [Stop] is respectively an indicator LED. If the green LED
flashs above the [Start]-button it signalizes that the labeler is ready. The red LED (above
[Stop]) shows an interruption of the labeling mode.

Program menus
The PROGRAMMING MODE may only be operated by trained
personnel!
̶ Wrong programmings may cause malfunctions!

The display controller of the Legi-Air 4050I comprises

three menu modes that can be reached and left by key
combinations. Push in stand-by-condition the following
buttons simultaneously to reach the following menu:
Fig. 7-5: Buttons below Display

[] + [Enter] = FUNCTIONS-MENU

[Enter] + [] = CONFIGURATIONS-MODE *
[] + [] = PROGRAMMING-MODE *
* Password protected

For more explanation here an example of a display message:

Firmware-Version Current configuration set Label

of controller counter

[Link] CFG01 00000

PRESSURE LOW E05

Status line

Fig. 7-6: Display explanation

ERROR ACKNOWLEDGEMENT s. Functions of the operator buttons [Start]/[Stop] on

page 60.

Indication of firmware version

The current firmware version (firmware = operating system) of the controller is displayed.
For more information please refer to the Firmware History on page 84).

Current configuration set

The Legi-Air 4050I provides the opportunity to store in memory up to 4 different configura-
tion sets. Each set can be used for an individual parameterization of the labeler (e.g. for
different production conditions).

Version: 10.12.14 Page 61 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Label counter
The number with 5 digits indicates the number of the completely performed application
cycles of one operation phase. The counter is reset to "0000" automatically when switch-
ing on the machine. If a negative number with 4 digits is displayed, the counter works in
“Countdown” mode.

Status line
The status line keeps you informed about the current conditions of the labeler and its ac-
tivities.
In labeling operation the status line provides at one glance the three most important in-
formation on current configuration set. For more detailed information, please see the
chapter “Troubleshooting”.

Stand-by mode
"After interruption of the labeling operation (e.g. [Stop]-button was pushed, or the protec-
tive cabinet was opened) the labeler changes to Stand-by mode. The vacuum to hold the
label is then turned off. A menu in the applicator’s controller can only be selected from
Stand-by mode

[Link] 7BB0
STAND-BY

FUNCTIONS-MENU
The functions menu is reached by pressing the [] und [Enter] key simultaneously, as-
suming the labeler is in emergency stop/standby by condition (see above). This menu
contains some basic settings of the labeler with following sub menus:

FUNCTIONS-MENU
...
LABEL-COUNTER
RST LABEL COUNT
DISPLAY SETTING
CHANGE LANGUAGE
EVENT-COUNTER
CYCLES SEQUENCE

Version: 10.12.14 Page 62 of 101 GB

 [Link] CFG1 00000
STAND BY

[Link] CFG1 00000

SELECT CONFIG: 001

Version: 10.12.14
CONFIGURATION 101 CONFIGURATION 109
Menü-Diagramm
BLOW TRIGGER: 000
Chapter 7 Operation

TRIGGER PRINT: 000

FUNCTIONS-MENU CONFIGURATION 102 CONFIGURATION 110

LABEL COUNTER 12345 TIMEOUT LABEL: 000 BLOW DELAY: 000

FUNCTIONS-MENU CONFIGURATION 103 CONFIGURATION 111

RESET L.-COUNTER VACUUM LEVEL: 000 BLOW TIME: 000

FUNCTIONS-MENU DISPLAY SETTINGS CONFIGURATION 104 CONFIGURATION 112

DISPLAY SETTING CHANGE LANGUAGE VACUUM TIMEOUT: 000 HOME TIMEOUT: 000
LCD-BRIGHTNESS
LCD-CONTRAST

CONFIGURATION 105 CONFIGURATION 113

EXTENS.-TRIGGER: 000 SYNC-PULSE DELAY000

Page 63 of 101
CONFIGURATION 106 CONFIGURATION 114
EXTENS. DELAY: 000 SYNC-PULSE TIME000
FUNCTIONS-MENU EVENT COUNTER
EVENT-COUNTER E00=12345
.
.
CONFIGURATION 107 CONFIGURATION 115
E22=12345 EXTENS. TIME: 000 BARCODE RD TIME: 000

EV1=12345678
. CONFIGURATION 116
CONFIGURATION 108
EV5=12345678
PROXIMITY [Link] 000 CYCLE OPTION: 000

FUNCTIONS-MENU CYCLE SEQENCE 2+3

CYCLE SEQUENCE ONLY CYCLE 2
ONLY CYCLE 3
NO CYCLE
CONFIGURATION 1..
PASSWORD:

CONFIGURATION ...

GB
40001851 BTA Legi-Air 4050I
Chapter 7 Operation 40001851 BTA Legi-Air 4050I

LABEL COUNTER
This provides the opportunity to set a value in the range of 0 to 9999 for the label counter.
If a value above "0000" is entered, the countdown function is activated. That means in
normal operating conditions the entered value is decremented. The display shows a mi-
nus sign in front, for the remaining application cycles. If "-0000" is reached, the machine
automatically stops the execution of labeling.

FUNCTIONS-MENU
LABEL COUNT 01234

¥ Press either [] or [] key* to move to the next parameter.

¥ Press the [Enter] key to edit the fore digits resp. press again [Enter] to change to the
last digits.
¥ Then press either [] or [] key* to move to the editing parameter values (corre-
sponding cursor is flashing) in order to increase and/or reduce.
¥ To exit parameter settings, press the [Start] or [Stop] key.

RESET LABEL COUNTER

This function resets the read value of the label counter.

FUNCTIONS-MENU
RST LABEL COUNT
¥ Press either [] or [] key* to move to the next parameter.
¥ Press [Enter] to reset the counter to "00000".
¥ To exit parameter settings, press the [Start] or [Stop] key.
*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 64 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

DISPLAY SETTING
This sub menu covers the display settings. Not only contrast and brightness can be
changed but also the menu language. Depending on language package, the following
languages are available:
Language package 1 (22800870): English, German, Italian, French, Dutch, Norwegian,
Swedish, Turkish
Language package 2 (22800871): English, Greek, Russian, Czech, Latvian, Polish, Span-
ish, Portugese

FUNCTIONS-MENU
DISPLAY SETTING
¥ Press either [] or [] key* to move to the next parameter
¥ Press [Enter] to get access to the sub menu "display setting (go on s. b.).
¥ To exit parameter settings, press the [Start] or [Stop] key.

Parameter of DISPLAY SETTING:

- LCD-BRIGHTNESS >> Brightness of background lighting
Value range is 001-040.
- LCD CONTRAST >> Contrast setting ranges 001-100

DISPLAY SETTING
CHANGE LANGUAGE
[] LCD-BRIGHTNESS: 015
[] LCD-CONTRAST: 030

¥ Press either [] or [] key* to move to the next display setting
¥ Press [Enter] to change the requested parameter
¥ At language selection the setting is changed by pressing [Enter] key
¥ In case of values press either [] or [] key* in order to increase and/or reduce the
editing parameter values (corresponding cursor is flashing).
¥ To confirm your settings, please press [Enter].
*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 65 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

EVENT COUNTER
This function allows displaying counters of various types of events that are automatically
tracked by the machine during operation and that may be source of useful statistic infor-
mation.

Event Counter indications

E00 Number of stopped labeling cycles without error.
E01 to E22 Number of occurred failures of the appropriate error codes (s. page 93 ff).
EV1 *7 number of labels printed.
EV2 *7 number of extension movements of the cylinder.
EV3 *7 number of blow-off procedures.
*7 number of internal communication errors detected (incl. autom. recovered er-
EV4 rors).
EV5 *7 maintenance counter increases by 1 after termination of 256 labeling cycles

*7 All counter values are stored in non-volatile memory only when the machine passes in
stand-by or in error condition. If the machine is systematically turned off while it is in
"ready" mode, EV1 to EV5 may not be updated correctly and show significantly lower fig-
ures than the topically happened events.

FUNCTIONS-MENU
EVENT COUNTER
¥ Press either [] or [] key* to move to the next parameter
¥ Press [Enter] to display the event counters

EVENT COUNTER
E00=00000
E01=00000 5-digit counter,
. Maximum value = 65535
. (after they roll back to 00000)
E22=00000
EV5=00000
[]
EV1=00000000 8-digit counter
. Maximum value: 99999999
[]
(after they roll back to 00000000)
EV4=00000000 )

¥ Press either [] or [] to display the next event counter

¥ To exit parameter settings, press the [Start] or [Stop] key
* auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 66 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

CYCLE SEQUENCE
This submenu enables the choice of sequences of labeling cycles to apply 2 labels one af-
ter another to a product. Requirement therefore is a particular applicator and that the func-
tion (programming 046) is activated. Classical application for pallet labeling.
(in standard configuration is valid: cycle 2 = front side labeling // cycle 3 = side labeling. If
your system provides the option “External Choice of Cycle Sequence” via Interface Sig-
nals, the external choice takes priority over the manual choice )

FUNCTIONS-MENU
CYCLE SEQUENCE
¥ Press either [] or [] key* to move to the next parameter
¥ Press [Enter] to get to cycle settings
¥ To exit parameter settings, press the [Start] or [Stop] key

Parameter of CYCLE SEQUENCE

CYCLE SEQUENCE
CYCLE SEQ. 2+3
ONLY CYCLE 2
ONLY CYCLE 3
NO CYCLE

¥ Press either [] or [] key* in order to change to the next cycle type.
¥ To confirm your settings, please press [Enter].

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 67 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

CONFIGURATION-Menu
To enter configuration menu press [Enter] and [] key simultaneously, if the labeler is in
"stand by" operation.
This menu contains parameter settings for the entire configuration of the labeler which de-
fines the print and apply sequence. The Legi-Air 4050I enables to store in memory up to 4
different machine configurations (parameter sets). The first function in the configuration
menu allows choosing the desired configuration with the available range is 0 to 3.

Note! On page 82 you have the opportunity to record all your parameters into a list.

SELECT CONFIGURATION (SELECT CONFIG.)

[Link] CFG01 01234

SELECT CONFIG 001
¥ Press either [] or [] key* to select the desired configuration 0-3 from the 4 possi-
ble ones.
¥ To exit Select Config, press the [Start] (for labeling operation) or [Stop] (for standby)
key.
¥ Press [Enter] in order to move to the selected configuration.
CONFIGURATION-Parameter
The display shows in the first line behind "CONFIGURATION" a number with 3 digits (e.g.
"101"). The first of the digits (left) indicates the current selected configuration (0-3). The
following two digits (01-16) represent consecutive numbering of the 16 configuration pa-
rameters.

CONFIGURATION 101
...
The 2nd line indicates one of following configuration parameter:

PRINT TRIGGER x01 BLOW-TRIGGER x09

LABEL TIMEOUT x02 BLOW DELAY x10
VACUUM LEVEL x03 BLOW TIME x11
VACUUM TIMEOUT x04 HOME-TIMEOUT x12
[Link] x05 SYNC-PULSE DELAY x13
EXTENSION DELAY x06 SYNC-PULSE TIME x14
EXTENSION TIME x07 BARCODE RD TIME x15
PROXIMITY [Link] x08 CYCLE OPTIONS x16

x = Configuration 0…3

Version: 10.12.14 Page 68 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

PASSWORD: 000
If one configuration parameter is called up with [Enter] in order to change, the machine
asks for a PASSWORD to proceed, in order to limit access only to authorized persons.
The access code is "123", once correctly entered it remains valid until the machine is
switched off or reset by pressing [Stop] key two times.

[Link] CFG01 01234

PASSWORD: 000
¥ Press either [] or [] key* in order to increase or reduce the value.
¥ Press [Enter] to confirm your password input.
¥ With the valid password you will return to the configuration parameter
¥ With the invalid password appears "WRONG PASSWORD E15" in display.
¥ To exit parameter settings, press the [Start] or [Stop] key

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

PRINT TRIGGER : 001

This parameter defines the start for printing a label. The signal is received by the labeler
either directly from the product sensor input of the corresponding M12 jack or from the
signal interface. Both inputs (M12 plug and I/O signal interface) are internally connected in
"WIRED OR" configuration so both signals are equal, whereby only one of both may be
used for triggering.
Different input configurations are available (edge and level triggering). Highest labeling
security is guaranteed by the cycle control check function. The status of the trigger signal
is checked in order to ensure that it is inactive when the trigger for continuation of the la-
beling cycle (in this case for printing) is expected.
If the signal is at this point of time still active (or again active), the labeler changes to fail-
ure and allows the detection of possible synchronization problems at critical applications.
The following table shows the function of the corresponding parameter value:
Para-
meter Function
Value
00 Prints automatically (if print data available)
01 Primary Sensor Input / (I/O: Pin 17) Edge-Triggering (leading edge):
02 Secondary Sensor Input /(I/O: Pin 23) Activation at leading edge, thus the change
from "low" to "high". Only when the display
03 Aux.-Input on I/O Interface: Pin 19 shows "Wait Trigger" a trigger is expected.
Internal Jumper at the Applicator PCB Otherwise incoming triggers are simply
04
ignored.
…

Version: 10.12.14 Page 69 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Para-
meter Function
Value
…
05 Primary Sensor Input / (I/O: Pin 17)
06 Secondary Sensor Input /(I/O: Pin 23) Level-Triggering (leading edge):
07 Aux.-Input on I/O Interface: Pin 19 Activation at "high" signal. Cycle repetition
as long as the signal stays active (high).
Internal Jumper at the Applicator PCB
08 J5,5
09 Primary Sensor Input / (I/O: Pin 17) Edge-Triggering with cycle monitoring (lead-
ing edge):
10 Secondary Sensor Input /(I/O: Pin 23) Same as Edge-Triggering (leading edge)
plus synchronization protection.
11 Aux.-Input on I/O Interface: Pin 19
Issue of monitoring: Signal must be "low"
Internal Jumper at the Applicator PCB before start of application cycle. Otherwise
12 J5,5 the Legi-Air 4050I changes into error condi-
tion.
13 - 16 Parameterization not allowed

17 Primary Sensor Input / (I/O: Pin 17) Edge-Triggering:

18 Secondary Sensor Input /(I/O: Pin 23) Activation at trailing edge, thus the change
from "high" to "low". Only when the display
19 Aux.-Input on I/O Interface: Pin 19
shows "Wait Trigger" a trigger is expected.
Internal Jumper at the Applicator PCB Otherwise incoming triggers are simply
20 J5,5 ignored.
21 Primary Sensor Input / (I/O: Pin 17)
22 Secondary Sensor Input /(I/O: Pin 23) Level-Triggering:
23 Aux.-Input on I/O Interface: Pin 19 Activation at "low" signal. Cycle repetition
Internal Jumper at the Applicator PCB as long as the signal stays active (low).
24 J5,5
25 Primary Sensor Input / (I/O: Pin 17) Edge-Triggering with cycle monitoring (trail-
ing edge):
26 Secondary Sensor Input /(I/O: Pin 23)
Same as Edge-Triggering (trailing edge)
Aux.-Input on I/O Interface: Pin 19 plus synchronization protection.
27
Issue of monitoring: Signal must be "high"
Internal Jumper at the Applicator PCB before start of application cycle. Otherwise
28 J5,5 the Legi-Air 4050I changes into error condi-
tion.
29 - 32 Parameterization not allowed

CONFIGURATION x01
PRINT TRIGGER : 001
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (valid range is: 000-032).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.
*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 70 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

LABEL TIMEOUT: 255

Its value determines the remaining time within the print of the label has to be started be-
fore the Legi-Air 4050I changes to error condition. Decisive for detection is the print signal
of the print module. The timeout starts on request of the labeler by (external or automatic)
triggering of the print. A specific cycle option (s. page 80) allows skipping error E09 if this
had to appear when a print request issued to the printer (input signal PRINT) without
available print data.
At value “000” the print signal will not be checked. This service function saves consuma-
ble material at adjustment works at the applicator. Thus the labeling cycle starts without
label (presumed that vacuum check is disabled)

CONFIGURATION x02
TIMEOUT LABEL: 255
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value = "255" waits forever, at value
“000” the cycle starts without label).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

VACUUM LEVEL: 005

This parameter determines the threshold for label presence detection on tamp. The high-
sensitive detector recognizes least leakages of pressure what results into a practicable
range of adjustment of 0-10 units. If the value "003" is entered a sufficient vacuum check
is realized. Values beyond, belong to the sensitive or high-sensitive measure range.

CONFIGURATION x03
VACUUM LEVEL: 005
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 1/33 bar, value = "0" disables the function).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 71 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

VACUUM TIMEOUT: 200

This parameter determines the maximum time delay the Legi-Air 4050I will try to detect
label presence on tamp by sensing the vacuum in the tamp before generating an error
message. This means the achievable vacuum has to be complete within the adjusted
time, otherwise an error occurs. Normally the vacuum is controlled after printing proce-
dure. For particular applications, the value can be set to “000” whereby the examination of
the vacuum is started together with printing.

CONFIGURATION x04
VACUUM TIMEOUT: 200
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value = "0"). Sudden examination of vac-
uum at value = "255" the labeler waits forever until the vacuum is created (200 =
2 seconds = default).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

EXTENS-TRIGGER : 000
This parameter defines the trigger signal used to activate the tamp extension. After the la-
bel was printed and detected at the Tamp, is the point in the operating cycle that the trig-
ger is expected. The mode in which the signal is processed is comparable to the PRINT
TRIGGER, so please refer to the table on page 69.

Para-
meter Function
Value
00 Applicator extends automatically (without any delay)
01 Primary Sensor Input / (I/O: Pin 17) Edge-Triggering (leading edge):
02 Secondary Sensor Input /(I/O: Pin 23) Activation at leading edge, thus the change
from "low" to "high". Only when the display
03 Aux.-Input on I/O Interface: Pin 19 shows "Wait Trigger" a trigger is expected.
Internal Jumper at the Applicator PCB Otherwise incoming triggers are simply
04
ignored.
05 Primary Sensor Input / (I/O: Pin 17)
. Level-Triggering (leading edge):
. Activation at "high" signal. Cycle repetition
continuation ref. page 69. as long as the signal stays active (high).

29 - 32 Parameterization not allowed

Version: 10.12.14 Page 72 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

CONFIGURATION x05
EXTENS.-TRIGGER:
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (valid range is: 000-032).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

EXTENSION DELAY: 000

This parameter is used to introduce a programmable time delay between the trigger signal
and the effective extension of the tamp. The delay is activated with the external/automatic
trigger pulse. The EXTENSION DELAY is ignored if parameter EXTENS. TRIGGER is set
to "000" (ref. page 72).

CONFIGURATION x06
EXTENSION DELAY 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value "000" = no delay).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 73 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

EXTENSION TIME: 080

The "EXTENSION TIME" defines the duration of the tamp extension phase, the time be-
tween tamp movement and start of air blast. If "000" is entered, the labeler is set to the
Blow-On mode so that the label is directly blown onto the product without further applica-
tor movement.
The dimensioning of the time value (unit = value x 10ms) should be matched to the effec-
tive time it takes to execute the extension of the complete stroke length.
If the entered EXTENSION TIME is exceeded by another parameter setting then the label
will be immediately applied onto the product, unless the labeler waits for a trigger signal
(e. g. "BLOW TRIGGER" see page 76 or proximity sensor "variable stroke"). In case of
variable stroke option the EXTENSION TIME is usually set to a small value (e.g. "002") to
be able to continue with the variable area of the stroke after a constant extension length.

CONFIGURATION x07
EXTENSION TIME: 080
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Press then either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value "000" = Blow-On mode).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 74 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

PROXIMITY TIMEOUT: 000

Any parameter value above "000" activates the "variable stroke" function, assumed the
optional proximity sensor is installed at the tamp plate. The entered value defines the
maximum time delay the applicator will wait during tamp extension, in order to detect the
approaching product surface. Otherwise the error message E14 is generated. The waiting
time is shown and decremented.
A specific cycle option (s. page 80) allows to skip the timeout error. For this case the label
is blown off and the Legi-Air proceeds with cycle as usual.
At a parameter value of “255”, the system waits unlimited for the trigger of the proximity
sensor (the time is then not displayed).

CONFIGURATION x08
[Link]: 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 100ms, if variable stroke is not installed the val-
ue should be set to "000", at value “255” waits unlimited).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 75 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

BLOW-TRIGGER: 000
This parameter defines the trigger signal for the label air blast. If "000" is entered the cycle
proceeds immediately the blow to apply the label undelayed respectively automatically.
Higher values stop the applicator at this point and wait for the predefined trigger signal.
Furthermore the incoming trigger can be used for remote start or remote stop of operation
corresponding to the configuration (of “programming”).
The mode in which the signal is processed is comparable to the PRINT TRIGGER.
If the variable stroke option is installed at the Legi-Air 4050I, the value must be set to
"000" (default).
Para-
meter Function
Value
00 Automatic blow-off the label
01 Primary Sensor Input / (I/O: Pin 17) Edge-Triggering (leading edge):
02 Secondary Sensor Input /(I/O: Pin 23) Activation at leading edge, thus the change
from "low" to "high". Only when the display
03 Aux.-Input on I/O Interface: Pin 19 shows "Wait Trigger" a trigger is expected.
Internal Jumper at the Applicator PCB Otherwise incoming triggers are simply
04
ignored.
05 Primary Sensor Input / (I/O: Pin 17)
. Level-Triggering (leading edge):
. Activation at "high" signal. Cycle repetition
continuation ref. page 69. as long as the signal stays active (high).

29 - 32 Parameterization not allowed

CONFIGURATION x09
BLOW-TRIGGER: 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (valid range is: 000-032).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 76 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

BLOW DELAY: 000

This configuration parameter delays the blow procedure by the entered value. This setting
is ignored if the previous parameter "BLOW TRIGGER" is set to "000".

CONFIGURATION x10
BLOW DELAY: 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value "000" = no delay).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

BLOW TIME: 050

This parameter is used to define the blow time and with it the duration of the solenoid
valve activation to blow the label onto the product. Allowed range is 010 to 255 (value x 1
ms).
Lower values allow reducing the cycle time, thus potentially increase the productivity of
the machine in high speed applications, but this makes the machine more sensitive to en-
vironmental points (temperature, presence of oil in the air supply). Higher values would in-
crease cycle time, not only for the increased pulse length, but mostly because the air tank
(inside the Legi-Air 4050I) discharges more deeply and requires more time to fully re-
charge and get ready for the next cycle.

CONFIGURATION x11
BLOW TIME: 050
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 1ms, value "000" = "Tamp On" mode and no
blow activation).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 77 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

HOME TIMEOUT: 000

This parameter determines the maximum time delay the applicator will wait during tamp
retraction for activation of the home sensor before an error is generated. This applies to
the case after the system was switched on and the tamp could not reach home position
because e. g. the air supply is still turned off.

CONFIGURATION x12
HOME TIMEOUT: 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 100ms, value "000" = no home position check,
value "255" = wait forever for the home signal).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

SYNC PULSE DELAY: 000

The SYNC signal is available at the I/O Interface (ref. page 48). Usually it starts at the end
of an operation cycle when the tamp arrives in home position. Using this parameter delays
the pulse start in order to activate for example a downstream pusher unit to push on la-
bels. For each unit a delay of 10 ms is introduced (i.e. maximum delay is "255" = 2.55
seconds).
In combination with the SYNC-PULSE TIME = 000 (s. below), the SYNC signal is activat-
ed at the set time delay and ends with the arrival of the tamp in home position (e.g. for use
as busy signal = "cycle currently active"). For more information refer to "SYNC-PULSE
TIME".

CONFIGURATION x13
SYNC-PULSE VDELAY000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value "000" = no delay).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 78 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

SYNC PULSE TIME: 005

This parameter determines the duration of the SYNC signal available at the I/O Interface
(s. page 48).
Normally the SYNC pulse starts at the end of cycle, when the tamp is completely retracted
to home position. The duration of the pulse corresponds to each entered value x 10 ms.
If the value is set to "000" the SYNC signal is event-controlled. If the SYNC PULSE DE-
LAY is also set to zero, the SYNC signal is activated with the first relevant trigger of a cy-
cle and deactivated as soon the tamp is retracted to home position (For this case the
SYNC output can be used as trigger acknowledge signal).
With SYNC PULSE DELAY greater than zero, the signal is activated after the correspond-
ing set delay time.
The following graphic shows the relationship between SYNC PULSE ... ... DELAY and
TIME:

Fig. 7-7: SYNC-Diagram

Pos. Description
A ACTIVE
P PASSIVE
CT CYCLE TIME
SPD SYNC PULSE DELAY
SPT SYNC PULSE TIME

CONFIGURATION x14
SYNC PULSE TIME: 005
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms, value "000" = see description above).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 79 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

BARCODE RD TIME: 000

If the labeler is equipped with an optional barcode scanner located at the tamp, this pa-
rameter is used to set reading time. The duration corresponds to each entered value x 10
ms (i.e. max. "255" = 2.55s). In case of using a gap barcode scanner (which scans the
barcode in the gap between printer and tamp, during the printing process) the time must
be set to "000".

CONFIGURATION x15
BARCODE RD TIME: 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (unit = value x 10ms).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 80 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

CYCLE OPTIONS: 000

This parameter is used to select some predefined operating cycle variants. The variants
can be combined with each other by means of the arithmetic sum or they can be activated
separately:
+ 1 enables the "variable stroke" resp. “label on tamp” within the variable stroke
timeout
+ 2 delays tamp retraction at the end of the blow phase (normally the tamp retracts at
the same time the blow valve is activated);
+ 4 disables the "variable stroke" feature and ignores vacuum loss during tamp ex-
tension;
+ 8 enables "corner-wrap" labeling function on machines equipped with the optional
90°-180° swing-arm (option);
+ 16 enables in Tamp-On mode (with blow time = "000", s. page 77) label presence
check (by vacuum) after application (when tamp retracts);
+ 32 enables the RFID feature to control the Reject Unit. If this function is used the
printer status check must be disabled (Programming 004, value "+016") other-
wise the labeler stops with error when a bad-tag is detected;
+ 64 disables the "label timeout" error (this may be necessary to disable vacuum
check to avoid its error);
+128 disables the proximity timeout error.

CONFIGURATION x16
CYCLES OPTION: 000
¥ Press [Enter] to get access to the menu "configuration" (if password is requested
please refer to page 69).
¥ Then press either [] or [] key* in order to increase and/or reduce the editing
parameter values (value: "000" = no operating cycle variant available, "001" = 1st
function; "002" = 2nd function; "003" = 1st and 2nd function...).
¥ To confirm your settings, please press [Enter].
¥ Press either [] or [] key* to move to the next configuration parameter.
¥ To exit configuration settings, press the [Start] or [Stop] key.

*auto-repeat function: For quickly make large changes, hold either [] or [] key.

Version: 10.12.14 Page 81 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Parameter list of configuration CFG 0-3

This list provides the possibility to record all parameters of the Configuration Menu (s.
page 82ff). A total of 4 parameter sets are available.

Product/ Charge/ Line >

Value of Value of Value of Value of

Configuration-Parameter
CFG 0.. CFG 1.. CFG 2.. CFG 3..

..01 PRINT TRIGGER

..02 LABEL TIMEOUT

..03 VACUUM LEVEL

..04 VACUUM TIMEOUT

..05 [Link]

..06 EXTENSION DELAY

..07 EXTENSION TIME

..08 PROXIMITY [Link]

..09 BLOW -TRIGGER

..10 BLOW DELAY

..11 BLOW TIME

..12 HOME-TIMEOUT

..13 SYNC PULSE DELAY

..14 SYNC PULSE TIME

..15 BARCODE RD TIME

..16 CYCLE-OPTIONS

Version: 10.12.14 Page 82 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

PROGRAMMING
Wrong parameters can lead to bugs and improper functions, also
possibly leading to mechanical damage.

This applies also in changes of reserved or undocumented pa-

rameters as well as entering values outside the valid ranges
̶ The programming mode should only be edited by authorized
and trained personnel!

The PROGRAMMING mode allows the consideration of all 256 service parameters and
enables the access to a further sub-menu. For a change of the values, a 5-digit password
has to be entered.

DIAGNOSTICS
The diagnostics function is accessible, when the machine is in stand-by or in error condi-
tion, by simultaneously pressing the [], [Enter], [] keys. The same happens if any key
is pressed while the machine is switched-on. The display changes to a numerical display
looking as follows:
1 3 6 9 12 15 18

2E00030000B800010000
040200 040157 000000
1 3 6 8 12 15 18 20

To exit the diagnostics function, press simultaneously the keys [Start] + [Stop] of the dis-
play, whereas at the same time a re-initialization is carried out.

Most of the numbers have little meaning for the average technician, but few of them may
be useful to diagnose common problems of the machine.

Please consider a 5% tolerance on the above mentioned pressure/vacuum values.

Upper line
¥ the first line show status information aa to ll of status strings (for details refer to the
service manual) sent via USB port.
Lower line
¥ the first 6 digits represent the communication error counters.
¥ the 3 digits in 8th to 10th position show the analog value measured by the vacuum
sensor (each unit corresponds to about 1/33 bar). Whereas the vacuum value is dis-
placed so that the value “041” is displayed with standard ambient pressure. Values
lower than 41 indicate vacuum in the tamp, down to a theoretical minimum of 008 for
absolute vacuum, while values above 41 indicate pressure in the tamp (normally a
short pulse during blow off procedure).
¥ the 3 digits in 11th to 13th position of the second line show the analog value measured
by the air-supply pressure sensor (each unit corresponds to about 1/33 bar).
¥ the following 4 digits in 15th to 18th position show status information mm to nn of sta-
tus strings (for details refer to the service manual) sent via USB port.
¥ the last 2 digits in position 19 to 20 represents the code of pressed keys of the dis-
play (if available).

Version: 10.12.14 Page 83 of 101 GB

Chapter 7 Operation 40001851 BTA Legi-Air 4050I

Firmware History
The firmware is the ‘’operating system’’ of the labeler’s control unit. Following is the
chronological order of all firmware releases (including changes) until the publication of this
Manual.

Version 4050.10 Creation date: 07. July 2011

Version 4050.09 Creation date: 09. February 2010

Version 4050.08 Creation date: 20. February 2008

Version 4050.07 Creation date: 30. November 2007

Version 4050.06 Creation date: 26. November 2007

Version 4050.05 Creation date: 08. March 2007

Version 4050.04 Creation date: 26. January 2007

Version 4050.03 Creation date: 03. August 2006

Version 4050.02 Creation date: 23. June 2006

Version 4050.01 Creation date: 10. May 2006

Version 4050.0 Creation year: 2006

Version: 10.12.14 Page 84 of 101 GB

Chapter 8 Maintenance/Service 40001851 BTA Legi-Air 4050I

8. Maintenance/Service

Safety regulations
Hazard from direct or indirect contact with voltage-
conducting parts.

DANGER TO LIFE!
̶ Disconnect the labeler from the mains voltage before working
on it.

Hazard from residual compressed air in the pneumatic com-

ponents.
Whipping compressed air hoses, thrown parts or uncontrolled
moving parts can cause injury.
̶ Disconnect the labeler from the compressed air supply before
working on the labeler.

Danger to health from the improper use of lubricants and

cleaners.

HEALTH HAZARD!
Improper use may lead to health hazards.
̶ The instructions in the manufacturer's current safety data
sheets for the specific lubricants and cleaners that are used
must be observed along with the applicable safety and dis-
posal regulations.

Damages of machines and machine parts

Failed or faulty maintenance/service- and repair works reduce
the operational availability of the machine. This may result in
subsequent damages and exclusion from warranty claims.

The machine functions must be continuously monitored.

Unusual noise or movements (such as bucking, hammering,
etc.) are indicative of malfunctions and must be investigated.
̶ All noticed defects have to be eliminated immediatly and pro-
fessionally.
̶ The operation of the machine is forbidden particularly at de-
fects at safety equipment until the defects are repaired cor-
rectly.
̶ The labeler’s maintenance/service is only permitted to ex-
perts. Only cleaning works may be arranged by operators
(Authorized persons s. page 21)

Version: 10.12.14 Page 85 of 101 GB

Chapter 8 Maintenance/Service 40001851 BTA Legi-Air 4050I

Daily maintenance/service (After approx. 8 hours of operation)

Requirements
¥ Labeler is disconnected from energy and compressed air
¥ No transportation of products

Required equipment
¥ Alcohol (*21800915) and/or roller solvent (*21800977)
¥ Lint-free cloth (*21800978)
¥ Label remover (*21800771)
* Product recommendation! Can be ordered at the Bluhm Weber Group by 8-digit article number.

Instruction
Please arrange the daily maintenance/service as follows.

Step Procedure
1 Clean the print head and feed roller either daily or each time you change the
roll. Spray some of the roller solvent onto a lint-free cloth and clean the rub-
ber rolls. Ensure before reloading print material that everything is dried.

2 Examine the label guidings and deflection rollers as well as the peeler bar
for excessive adhesive build up/label rests. Clean if necessary, with label
remover or alcohol.

3 Examine the drain valve of the air pressure connection. Drain and eliminate
the source of water/oil if possible by opening the valve at the bottom.
A lot of water in drain valve is a hint that the operating air pressure is not
working correctly. Water/oil – mixtures in drain valve have to be considered
as an alarm signal! The reason has to be examined. If oil flows in the air
pressure circle, it will lead generally to failures! Maintenance to this filter will
be greatly reduced if you use an adequate pre-filter (for 300l/minute flow rate
at 7bar, 10 µm).

4 Examine the tamp surface and the peeler bar for possible adhesive resi-
dues. Remove them with label remover or alcohol.

5 Examine / clean the air filter from the protective cabinet (if option available).

Version: 10.12.14 Page 86 of 101 GB

Chapter 8 Maintenance/Service 40001851 BTA Legi-Air 4050I

Weekly maintenance/service (After approx. 40 hours of operation)

Requirements
¥ Labeler is disconnected from energy and compressed air
¥ No transportation of products

Required equipment
¥ Alcohol (*21800915) and/or roller solvent (*21800977)
¥ Lint-free cloth (*21800978)
¥ Label remover (*21800771)
¥ Compressed air spray (*21800768)
¥ Soft brush (round or plain approx. 10 mm)
* Product recommendation! Can be ordered at the Bluhm Weber Group by 8-digit article number.

Instruction
Please arrange the weekly maintenance/service as follows.

Step Procedure
1 Clean the tamp surface, the peeler bar and all paper guiding parts from ad-
hesive using label remover or alcohol.

2 Clean all sensors (product sensor, low label sensor and label gap sensor)
carefully with a soft brush or compressed air spray.
Do not use air pressure from the shop air supply to blow dust from the ma-
chine. 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 and fixed position, correct if
necessary.

4 Remove dust from the system cabinet.

5 Examine all roller assemblies for free rotation, excessive play, etc., and cor-
rect if necessary.

6 Examine the mechanics of the linear- resp. swing unit and the tamp for
tightness and possibly solved screws.

Version: 10.12.14 Page 87 of 101 GB

Chapter 8 Maintenance/Service 40001851 BTA Legi-Air 4050I

Six-Month maintenance/service (After approx. 1000 hours of operation)

Requirements
¥ Labeler is disconnected from energy and compressed air
¥ No transportation of products

Required equipment
¥ Vacuum cleaner

Instruction
Please arrange the six-month maintenance/service as follows

Step Procedure
1 Replace the air filter elements (if available).

2 Clean the system cover outside and the protective cabinet (if available) in-
side using an industrial vacuum cleaner.
Do not use air pressure from the shop air supply to blow dust from the ma-
chine. There is a possibility that this air can contain water and emulsified oil,
which can damage the electrical components in your machine!

3 Check the home position sensor. Fix if loose.

Yearly maintenance/service (After approx. 2000 hours of operation)

Requirements
¥ Labeler is disconnected from energy and compressed air
¥ No transportation of products

Required equipment
¥ Proline, Pro 672U Food Grease (*92100772 food-compliant)
* Product recommendation! Can be ordered at the Bluhm Weber Group by 8-digit article number.

Instruction
Please arrange the yearly maintenance/service as follows.

Step Procedure
1 Examine label liner rewinder for excessive wear. Check all timing belts for
wear and correct tension. Exchange all parts that are necessary for a correct
function.

2 Check all moving parts for wear and bearing clearance. Replace if worn.

3 Only systems with linear stroke: Clean the guide rods and lubricate it thin.

Version: 10.12.14 Page 88 of 101 GB

Chapter 8 Maintenance/Service 40001851 BTA Legi-Air 4050I

Spare parts

Hazard from incorrect spare parts!

Incorrect or faulty spare parts can impair safety and cause injury or
damage to the machine.
̶ Only use original spare parts or parts that are specifically ap-
proved by the Bluhm Weber Group.

The (standard) spare parts of the labeler Legi-Air 4050I are included in a separate docu-
mentation and belong to the scope of supply.

Wiring- and pneumatic diagrams

The standard wiring and pneumatic diagram of the labeling system is included in spare
part documentation.
Diagrams with customer-specific information are either included in the switch cabinet or
are in the documentation folder.

Cleaning Notes
s. next page

Version: 10.12.14 Page 89 of 101 GB

Chapter 8 Maintenance/Service 40001851 BTA Legi-Air 4050I

REINIGUNGSHINWEISE / CLEANING NOTES

DE GB

REINIGUNG NACH CLEANING AFTER EACH

JEDEM ROLLENWECHSEL ! ROLL CHANGE !

BESTELL-NUMMERN / ORDER NUMBERS

FLUSENFREIES TUCH
ETIKETTEN-LÖSER

REINIGUNGSFOLIE
COMPRESSED AIR

WALZENOEINIGER
ROLLER-SOLVENT

LINT-FREE CLOTH
LABEL REMOVER

DRUCKLUFT

LAP SHEET
ALCOHOL
ALKOHOL

BESTELLANNAHME
ORDER PROCESSING

DRUCKKOPF / PRINTHEAD FRIKTIONSEINHEIT / FRICTION UNIT

TISCHDRUCKER
DESKTOP PRINTER GUMMIWALZEN / PLATEN ROLLERS SENSOREN/ SENSORS

SPENDEKANTEN / PEELER BARS

DRUCKMODULE
PRINT MODULES

ANTRIEBSWALZE / DRIVER ROLLER ANDRÜCKWALZEN

PRESSURE ROLLERS

FRIKTIONSWALZE / FRICTION ROLLER

ETIKETTIERER
LABELER

AUF- & ABSPULERACHSEN FÜHRUNGSROLLEN/ GUIDE ROLLERS

UN- & REWIND MANDRELS

ETIKETTIERER STÜTZLUFT-EINHEIT STEMPELPLATTE /TAMP PLATE

LABELER AIR ASSIST ASSEMBLY

Version: 10.12.14 Page 90 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

9. Troubleshooting
This chapter is divided into 2 parts; “Mechanic Failures” and “Messages by Display”. The
possible causes and their elimination are described in the following two passages.

The troubleshooting instructions, only address to trained technicians.

Mechanic failures

PROBLEM POSSIBLE CAUSE SOLUTION

Label liner tears Damage of label roll: Exchange label roll.
 Nicks or label cut-
ter-die damage
on liner.
 Dents/damages
at the side of the
label roll.
 Liner width varies
significantly.
Adhesive residues in the area Remove adhesive residues and
of the peeler bar. check the label roll for damages
caused by adhesive residues. Other-
wise exchange roll.
Labels are not being held Generation of vaccum (Ven- Check the vacuum. If necessary,
onto the tamp. Label place- turi) does not work. increase pressure and clean or re-
ment on the tamp is consist- place Venturi.
Air pressure too low.
ently poor.
Air assist pressure too high
or low.
Air assist tube is in wrong
position.

Label placement on the The product is not yet/ not Check sensors of the conveyor used
product is consistently poor. anymore incorrect labeling to determine the stop position.
position.

Product sensor (or its reflec- Check sensors and remount, if re-
tor) are loose or vibrate. quired.
Changing conveyor speed Check the speed and record. Contact
(e.g. depending on load) supplier of conveying system.
Label with not suitable adhe- Change label quality.
sive, insufficient initial adhe-
sion.
Wrong parameterization. Check time- and delay settings of the
responsible configuration parameters
(blow-, extension-…)
Air assist does not function or Air-pressure too high or low. Check air pressure (appr. 6 bar).
is not sufficient during the
transfer of the label to the Internal air pressure contain- Check the tank of the pneumatic
tamp… er leaky. system if it is sealed.

Version: 10.12.14 Page 91 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

PROBLEM POSSIBLE CAUSE SOLUTION

… Air assist does not function Air assist tube is wrongly Examine air assist setup or replace
or is not sufficient during the positioned, defect or not con- defective parts or inquire Service
transfer of the label to the nected correctly. Technician at the Service-Hotline (s.
Tamp… Fast discharge valve is de- page 8).
fect.
Controller failure. Contact the Service Hotline (s. page
8).
Operating sequence not pos- Printer jam. Open obstruction and re-thread la-
sible. Label will not be ap- bels.
plied.
Print module hasn't received Check message at the printer display
any data. to examine if print data available.
Incorrect print engine param- Check parameter on the basis of the
eter values. printer manual and system checklist
(as an appendix of this manual).
Tamp home sensor is not Examine sensor setup or inquire
functioning. Service Technician at the Service-
Hotline (s. page 8).
No triggering by customer Check incoming trigger signal. Coun-
PLC or product sensor. tercheck with [Enter] key.
Optional proximity sensor is Examine sensor or replace if neces-
not functioning. sary or inquire Service Technician at
the Service-Hotline (ref. page 8).
The desired rate of applica- The required rate of applica- Check conveyor speed and the prod-
tion cannot be reached with tion from the conveyor ex- uct gap; compare the values with the
the labeler… ceeds the specifications. specifications of the Legi-Air 4050I
regarding the stroke length. Reduce
conveyor speed if possible.
Incorrect configuration pa- Inquire Service Technician at Hotline
rameter values of the labeler. (s. page 8).
Excessive cycle processing
time.
Tamp speed too low. Optimize the flow control regulator
setup of the cylinder or inquire a Ser-
vice Technician at Service-Hotline (s.
page 8).
Excessive printer processing Ensure that maximum possible print
time. speed is used.
Check the possibility of optimizing the
layout data (e.g. outsourcing data to
Memory-Card, avoiding True-Type
fonts). For more information refer to
the printer manual.

Version: 10.12.14 Page 92 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

PROBLEM POSSIBLE CAUSE SOLUTION

Machine functions occur at Product detector loose or Check the adjustments of the sen-
random without being initiat- vibrating, or being affected of sors and inquire if needed a Service-
ed. reflecting light from product Technician at the Service-Hotline (s.
surface. page 8).
Loose wiring connections. Check all connections at labeler s.
page 41.
Incomplete label feed. Wrong print engine setup. Check calibration of label material
(according to printer manual).
Labels are not loaded cor- Control paper guiding in print engine
rectly. (according to printer manual) and at
labeler (s. page 51).
Powered rewinder is not Control the function of the dancer
switched off by rewinder arm. If the liner tenses, the rewinder
dancer arm. has to stop.
The unwinder brake is not Control the function of the dancer
approved by unwinder dancer arm. If the label web becomes more
arm. tense, the label roll has to be un-
winded easily.
No label feed possible. Tamp home sensor is broken Replace or adjust sensors as neeed-
or out of adjustment. ed or contact the Service-Hotline (s.
page 8).
Label fails to leave the tamp Fast discharge valve is de- Examine and replace defective part if
optimal. fect. necessary.

Optional proximity sensor Examine and replace sensor if nec-

switches too early or not at essary or inquire Service Technician
all. at Hotline (s. page 8).
Incorrect configuration of Check configurations from page 77>>
parameters concerning BLOW TIME too early, too short or
BLOW timing. wrong trigger.
Blow valve does not work Examine, clean the valve or replace
correctly. as needed.
Labels are printed continu- Missing synchronization due Compare the setup with the printer
ously. to wrong parameterization of manual or system checklist
the print engine. (as an appendix of this manual)
Poor print quality. Incorrect configuration or Follow the notes of the printer manu-
print media. Dirt at the print- al.
er.
Bad tags are not rejected by Incorrect configuration of Disable the printer error check or
reject device. Labeler chang- printer error check. inquire Service Technician at Hotline
es into error condition. (s. page 8).

Version: 10.12.14 Page 93 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

Error messages via display

The Legi-Air 4050I immediately stops operation if an error was detected or was stopped
by pressing the [Stop] key, and the labeler interrupts the application cycle. The machine
changes to stand-by mode, the green Indicator LED at the user panel turns off and the red
one illuminates. In the second line of the display appears an error message showing fol-
lowing description:

[Link] CFG01 00000

PRESSURE LOW E03

Error Reset
Acknowledge the error after its elimination by pressing the [Start]-key on the dis-
play and the Legi-Air 4050I changes to normal operating conditions. If instead the [Stop]
key is pressed, the labeler changes to settling time (same condition as after switching on).
In both cases it is guaranteed that the event is counted in the event counter (s. page 66).

NOT RESPONDING E01

The message indicates that one of the slave processors is not responding to master
commands, probably due to a connection problem (typically when the applicator cable is
disconnected) or due to a hardware fault. For analyzing the error the following steps
should be performed: in the mode programming 003 change the value (default 000) to
002. The display shows an error code instead of error E 01.
Values in a range of 50…52 point out to problems with the I/O-Board, values about
64…65 point out to applicator problems.

PARAMETERS ERROR E02

The message may be displayed just after switch-on and it indicates that the integrity
check performed on the parameters stored in the internal memory has failed. It is normal
to receive this message after a chip reprogramming or a factory default reset of the pa-
rameters. Possible cause: at repeated appearance, problems with data loss at the
memory chip of the slave processor.

PRESSURE LOW E03

The Legi-Air 4050I provides an air supply pressure sensor to monitor the air supply pres-
sure. If air supply pressure is not within the limits established for correct operation of the
machine, this message will occur. Possible cause: Defective air supply…. If it is okay, it
could be a defect at one of the internal pressure sensors…

PRESSURE HIGH E04

see above E03

HOME NOT FOUND E05

The above-mentioned message indicates that the home sensor detecting the "home" posi-
tion (fully retracted) of the application plate did not activate within the configured time limit
(HOME TIMEOUT, s. page 78) during the retraction phase. Possible causes: Incorrect ad-
justment of home sensor position, defective home sensor or cable, stroke mechanically
blocked….

Version: 10.12.14 Page 94 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

HOME ERROR E06

This error indicates that the home sensor did not deactivate within the configured time lim-
it (settable at programming 054 [for Config. 00]; 078 [for 01]; 102 [for 02] 126 [for 03] de-
fault value = "100" x 10 ms = 1s) at the beginning of the plate extension phase. Possible
cause: mechanical defectives at the cylinder avoid extension of the tamp….

TRIGGER ERROR E07

The message can be generated only if the trigger status check has enabled (by corre-
sponding parameterization of input trigger, ref. page 69) in configuration and it indicates
that the status of the selected trigger input was not returned to the inactive condition since
last activation or that it was activated too early, so that the applicator did not recognize the
active transition. Possible causes: contamination or incorrect adjustment of product sen-
sor, slow or none conveyance of the product, insufficient product distance, signal of one of
the product sensors is active before proximity sensor (if available) is activated at tamp….

PRINTER ERROR E08

The message indicates that just before or during printout, a FAULT signal was detected
from the printer, or that the PRINT signal was already active before the next label was re-
quested. Possible causes: ribbon end, printer paused, printer defective….

MISSING LABEL E09

The message indicates that the requested label did not start printing within the configured
time limit (ref. page 71). Possible causes: print data not available, label could not be print-
ed… .
If the inquiry “label on tamp” was activated (see value + “016”, page 80), the missing label
on the product is detected.

INSUFF. VACUUM E10

Behind “INSUFF. VACUUM E10" hides the "Label on Pad" examination. This means,
within the configured timeout (ref. page 72) the vacuum was insufficient or level subse-
quently dropped. Possible causes: label incomplete or not at the tamp >> due to an >> in-
correct Air Assist adjustment, unexpected removal of the label or to some other problem in
the pneumatic circuit (Venturi tube)….

VACUUM LOST E11

This message appears if after an incipiently successful "Label on Pad" examination, the
vacuum level drops down, under the configured limit (ref. page 71). Possible causes: un-
expected removal of the label, malfunction in pneumatic circuit….

MISSING BLOW E12

The message indicates that an abnormally weak pressure peak was detected in the tamp
during the blow phase. The minimum blow is controlled by "programming 14". Possible
causes: leakage or malfunction in the pneumatic circuit…

PEAK BLOW PRESS. E13

The message indicates that an abnormally high pressure peak was detected in the tamp
during the blow phase. The maximum blow is controlled by “programming 15” (default =
3,03 bar). Possible causes: typically some obstruction, like a label sticking on tamp,
blocked tamp perforation or malfunction in the pneumatic circuit….

PROXIMITY ERROR E14

The above-mentioned error indicates that the "variable stroke" sensor mounted on the
tamp (s. page 75) did not detect the approaching of the product's surface within the con-

Version: 10.12.14 Page 95 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

figured time limit during the extension phase. Or an object was detected too early in ex-
tension phase Possible causes: contamination or incorrect adjustment of proximity sensor,
sensor or cable broken, product feeding insufficient….

WRONG PASSWORD E15

Wrong password entered (s. page 69).

BARCODE READ ERR E16

The message is generated only if barcode feature is activated (programming 028, value >
“0”) and the barcode reader mounted on the tamp has reached the maximum scanning
repetition.

MAX RFID REJECTS E17

This message indicates that the maximum predefined number of consecutive or cumula-
tive rejected RFID labels and with this the maximum capacity of the reject device has
been reached.
Or, if programming 028 (value 001-127) is enabled the maximum of determined repeti-
tions was exceeded.

DOOR NOT OPENING E18

The slide (door) of the protective cabinet (option) could not be opened within the preset
time (programming 041). Possible causes: slide mechanically blocked, door open sensor
misadjusted/ damaged….

EMERGENCY STOP E19

Presumed that the labeler is equipped with the optional hardware, this message is dis-
played if the emergency stop circle is interrupted (e.g. by opening the safety door switch
of the safety device and/or the cabinet by pressing [Air Pressure "OFF"] of the remote but-
ton box).

REWINDER TIMEOUT E20

Presumed that the labeler is equipped with the generation of the intelligent rewinder
boards and accordingly configured (programming 003, value = “+008”), this message is
displayed if the dancer arm of the unwinder comes not to correct working position Possi-
ble causes: the liner paper is not reversed correctly by dancer arm and rewinder, there is
no tension or it is torn, defective rewinder motor, sensor or sensor flag….

Version: 10.12.14 Page 96 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

Status messages via display

The following status messages are shown at the display and they will be replaced by new
status or error messages. For clarification, the messages will be described in chronologi-
cal sequence, as they are displayed during the labeling cycle:
WAIT [Link] 01 or
WAIT [Link]. 01 or
WAIT [Link]. 01 or
WAIT BLOW TRIG 01

… are not error messages but status messages, to brief that a trigger signal is expected.
The ID number "01" at the end of line, specifies the corresponding input where the trigger
is expected. This means:

01 = primary; 02 = secondary; 03 = AUX …input (ref. also page 69).

If trigger delays have been set, immediately after the trigger signal has been detected, the
number on the right will show a 3-digit countdown indicating the elapsing delay time.

WAITING LABEL 100

This message appears where the number on the right is a 3-digit countdown that shows
the remaining time before an error will be generated if the printer does not start feeding a
label within the configured timeout.

LABEL PRINTING
This message is displayed during the print procedure, when the air assist jet pushes the
label against the tamp.

WAITING VACUUM 000

Vacuum is switched additionally in order to catch the label at the tamp. The number on the
right indicates in real time the current vacuum level ("000" means no vacuum, "020" to
"030" is the maximum vacuum level reachable, depending on air supply pressure). This
phase is normally very short, so the message is barely noticeable, but if there are aspira-
tion problems (mispositioned label or leakages on the pneumatic circuit), the message
lasts long enough to be readable (up to 2,55 seconds) and it may give some diagnostic
help, before Error E10 (s. page 95) appears.

REJECT RFID LBL 050

This message is displayed with activated RFID-Reject-Function (s. page 80), during Re-
ject-Unit is rejecting bad tags. The cycle changes automatically to "WAITING LABEL" –
stage in order to print a new label.

PLATE EXTENSION 080

The number on the right shows a 3-digit countdown, according to the configured duration
within the tamp should have left the home position.
If the labeler is equipped with a variable stroke sensor, at correct configuration (s. page
75) for a short moment of time of the plate extension time, the following status messages
are displayed:

Version: 10.12.14 Page 97 of 101 GB

Chapter 9 Troubleshooting 40001851 BTA Legi-Air 4050I

WAIT PROXIMITY 200

The number on the right is a 3-digit countdown that shows the remaining time (s. page
75), before the error E14 (s. page 95) will be generated if the sensor does not detect the
product within the configured timeout. At timeout-setting 255 = endless, the countdown
display is omitted.

READING BARCODE 050

During verifying the barcode the number on the right shows a 3-digit countdown, accord-
ing to the configured barcode reading.

PLATE RETRACTION 050

Assumed that the optional 90° swing tamp applicator and corner application have been
enabled, the message is temporarily displayed after having applied the label on the front
side, while the plate is wiping the label on the corner. The number on the right shows a 3-
digit countdown, according to the configured duration.

WAITING HOME 150

The number on the right shows a 3-digit countdown, according to the configured duration
(s. page 71), within the tamp should have reached home position once the label has been
blown onto the product. At timeout-setting 255 = endless, the countdown display is omit-
ted.
Once the plate has returned back in home position, the following message is displayed:

CYCLE COMPLETE 005

The number on the right is a 3-digit countdown that shows the SYNC PULSE duration (ref.
page 79). This phase is normally very short, so this last message is barely noticeable, be-
ing immediately overwritten by the first message of the next cycle.

MAINTENANCE!
The maintenance has to be arranged. The Hotline (s. page 8) is pleased to wait for your
order for a Service-Technician.
DOOR OPENING
This message is displayed when the slide (option) of the protective cabinet is opened for
tamp movement.

Version: 10.12.14 Page 98 of 101 GB

Chapter 10 Index 40001851 BTA Legi-Air 4050I

10. Index

Catchwords from A to Z

ACCESS CODE .................................... 69 Feed ...................................................... 10

Adhesive residue ................................... 87 Fine adjustments ................................... 40
Air Assist ................................................. 9 Firmware ............................................... 84
Air Assist Tube ........................................ 9 First steps.............................................. 53
Air Blast ................................................... 9 Food products ....................................... 14
Air filter element .................................... 88 Gap ....................................................... 10
Alarm lamp ............................................ 47 HOME ERROR ........................................ 95
Application modi .................................... 34 Hotline ..................................................... 8
BARCODE ERROR .................................. 96 Idle-Mode .............................................. 58
Batch-Operation .................................... 34 Installation site ...................................... 40
Blow time ............................................... 77 [Link] ........................... 95, 97
Case of an Emergency .......................... 13 Key combinations .................................. 61
Clean ..................................................... 87 Label liner tears..................................... 91
Configuration ......................................... 68 Label loading ......................................... 51
Connection and positioning of the product Label Out............................................... 10
sensor .................................................... 45
LABEL PRINTING ............................... 97
Connection to compressed air .............. 44
Labeling operation .......................... 58, 59
Connections .......................................... 42
Leakage ................................................ 87
Counter .................................................. 66
Legi-Air 4050I ........................................ 28
Cycle ....................................................... 9
Low Label ........................................ 10, 46
CYCLE COMPLETE ............................... 98
MAINTENANCE ...................................... 98
Default ..................................................... 9
MAX RFID REJECTS ........................... 96
Diagnostics function .............................. 83
Menu languages ................................... 65
Diagram ................................................. 89
MISSING BLOW .................................... 95
DIP Switches ........................................... 9
MISSING LABEL ................................. 95
Direct-Tamp-Mode ................................ 34
NOT FOUND .......................................... 94
DISPLAY SETTING......................... 65, 67
NOT RESPONDING ............................... 94
DOOR NOT OPENING ........................... 96
Oil-/water residue ............................ 87, 88
DOOR OPENING .................................... 98
Operation .............................................. 54
Dusty environment ................................ 14
Operation outdoors ............................... 14
Edge Detection ...................................... 10
Operator buttons ............................. 60, 61
EMERGENCY STOP ............................... 96
Operator personnel ............................... 25
Error messages ..................................... 94
PARAMETERS ERROR ........................... 94
Error reset ............................................. 94
Password .............................................. 69
Event counter .................................. 66, 94
PEAK BLOW PRESS. ........................... 95
Explosion risk area ................................ 14
PLATE EXTENSION ............................. 97

Version: 10.12.14 Page 99 of 101 GB

Chapter 10 Index 40001851 BTA Legi-Air 4050I

PLATE RETRACTION ........................... 98 Spare parts............................................ 89

Pneumatic diagram ............................... 89 Stand-by ................................................ 62
Poor label placement ............................ 91 Sufficient access ................................... 40
Poor label placement ............................ 91 Supply voltage connection .................... 43
PRESSURE HIGH .................................. 94 SYNC .................................................... 50
PRESSURE LOW .................................... 94 SYNC signal .................................... 78, 79
Print Engine ........................................... 28 System out of operation ........................ 60
Print engine connection ......................... 47 Tamp-Blow-Mode .................................. 34
Print engine types.................................. 27 Tamp-On-Mode ..................................... 34
PRINTER ERROR .................................. 95 Test function.......................................... 83
Printhead ............................................... 11 Timing belts ........................................... 88
Product Delay ........................................ 11 Trigger ................................................... 12
Product sensor P ................................... 45 TRIGGER .............................................. 69
Product sensor S ................................... 45 TRIGGER ERROR ................................. 95
Programming-Mode............................... 83 Unwinder ............................................... 12
Protective gear ...................................... 22 Vacuum ................................................. 83
Protective measure ............................... 17 VACUUM LOST ...................................... 95
PROXIMITY ERROR ............................. 95 Venturi ................................................... 12
Putting the system out of service .......... 59 Void ....................................................... 12
READING BARCODE ............................. 98 WAIT BLOW TRIG. ............................. 97
Ready / Alarm........................................ 50 WAIT PROXIMITY ............................... 98
REJECT LBL ........................................ 97 WAIT [Link]. ............................... 97
Reset error ............................................ 94 WAIT [Link]. ............................. 97
Rewinder ............................................... 11 WAIT [Link]. ............................... 97
REWINDER TIMEOUT ........................... 96 WAITING HOME .................................... 98
RFID-reject ............................................ 97 WAITING LABEL ................................. 97
Ribbon loading ...................................... 51 Wet environment ................................... 14
RoHS ..................................................... 18 Wiring diagram ...................................... 89
Scope of delivery ................................... 35 WRONG PASSWORD ............................... 96
Service hotline ......................................... 8

Version: 10.12.14 Page 100 of 101 GB

EC-Declaration of conformity 40001851 BTA Legi-Air 4050I

Only valid for labelers with factory limited tamp force (up to max. 50 Newton) or with additional Safety
11. EC-Declaration of conformity
Guarding according to machine directive 2006/42/EG (see Declaration of Incorporation, part of assem-
bly instructions). Otherwise it is forbidden to operate the partly completed machine.

DE EG-KONFORMITÄTSERKLÄRUNG, gemäß EG-Maschinenrichtlinie 2006/42/EG, Anhang II A

GB EC-DECLARATION OF CONFORMITY, according to EC Machinery Directive 2006/42/EC, Appendix II A
FR DÉCLARATION DE CONFORMITÉ CE, conforme à la directive machine 2006/42/CE, appendice II A
NO EU- SAMSVARSERKLÆRING, i henhold til EU-maskineridirektivet 2006/42/EC, Tillegg II A
DK EG-OVERENSSTEMMELSESERKLÆRING, i henhold til EU-maskindirektivet 2006/42/EF, bilag II A

Weber Marking Systems GmbH

Maarweg 33
D-53619 Rheinbreitbach

(DE) Wir erklären in alleiniger Verantwortung, dass das Druck-Spende-System

(GB) We declare under our sole responsibility that the print-apply-system
(FR) Nous déclarons sous notre responsabilité exclusive que le système d’application et d’impression
(NO) Vi erklærer på eget ansvar at skrive-mate-systemet
(DK) Vi erklærer som eneansvarlige, at print-apply-systemet

Legi-Air 4050I (CC)

(DE) auf das sich diese Erklärung bezieht, den Bestimmungen und Richtlinien
(GB) to which this declaration relates corresponds to the regulations and directives
(FR) que concerne cette déclaration, est conforme et aux directives
(NO) som denne erklæringen gjelder, er i overensstemmelse med bestemmelsene og direktivene
(DK) som denne erklæring refererer til, er i overensstemmelse med følgende bestemmelser og direktiver

2006/42/EG
2004/108/EG
2006/95/EG

(DE) und mit den folgenden Normen und norminativen Dokumenten übereinstimmt
(GB) and conforms with the standards or standardized documents
(FR) et en conformité avec les normes ou documents normalisés suivant
(NO) og følgende normer og standarder
(DK) og i overensstemmelse med de normer og standardiserede dokumenter, der er anført nedenfor

EN ISO 13849-1:2008/AC EN 349:1993+A1 EN ISO 13857:2008

EN ISO 12100:2010-11

(DE) Bevollmächtigter für die Zusammenstellung der relevanten technischen Unterlagen:

(GB) The person authorised to compile the relevant technical documentation:
(FR) La personne autorisée à élaborer la documentation technique nécessaire:
(NO) Personen som har fullmakt til å sette sammen den tekniske dokumentasjonen:
(DK) Autoriseret repræsentant for udarbejdelse af relevante tekniske dokumenter:

Lutz Krämer
Maarweg 33
D-53619 Rheinbreitbach

Rheinbreitbach, 05. Februar 2014

__________________________________
Eckhard Bluhm
Geschäftsführer /director / gèrant / [Link] /Amministratore

Version: 10.12.14 Page 101 of 101 GB