Weber LA 6000 Operating Manual 18.11.2019

Original instructions
Legi-Air 6000 V2
Material number of the documentation 40045925

Copyright ©, Weber Marking Systems GmbH
(GB) English
Version: 01.08.2018 /KRA
40045925
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: info@webermarking.de
http://www.webermarking.de
Blank page
Contents 40045925 BTA Legi-Air 6000 V2
Table of contents
1. General ................................................................................................................... 7
Overview ........................................................................................................................... 7
Limitation of liability ........................................................................................................... 7
Warranty conditions........................................................................................................... 7
Copyright........................................................................................................................... 7
Purpose and scope of the operating instructions ............................................................... 7
Notes on using the operating instructions .......................................................................... 8
Service Hotline .................................................................................................................. 9
Explanation of the technical terms ................................................................................... 10
2. Safety regulations ............................................................................................... 14

Behaviour in case of emergency ..................................................................................... 14
General safety regulations............................................................................................... 14
Meaning of the risk levels............................................................................................................. 14
Intended use ................................................................................................................... 15
Reasonably foreseeable misuse...................................................................................... 16
Conversions and modification of the labeling system ...................................................... 16
Sources of danger at the labeler...................................................................................... 17
Warning notices on the labeler ........................................................................................ 18
Safety instructions ........................................................................................................................ 18
Remaining risks............................................................................................................... 20
Disposal .......................................................................................................................... 21
Obligations of the operator .............................................................................................. 21
Approved persons ........................................................................................................... 22
Personal protective equipment ........................................................................................ 22
Protection device ............................................................................................................. 23
Machine cover .............................................................................................................................. 23
Separating and non-separating protection devices ..................................................................... 23
Emergency stop function ................................................................................................. 25
Activation of the emergency stop circuit ...................................................................................... 25
Control of applicator brake ........................................................................................................... 26
Monitoring .................................................................................................................................... 26
Workplaces for operating and technical personnel .......................................................... 26
3. Technical Specifications .................................................................................... 27

Information on further dimensions (SES linear applicator) .......................................................... 27
Information on further dimensions (SERO rotating applicator) .................................................... 27
Performance data (SES linear applicator) ................................................................................... 28
Performance data (SERO rotating applicator) ............................................................................. 28
Information about operating elements ......................................................................................... 28
Noise level .................................................................................................................................... 28
Details of compatible print module types ..................................................................................... 29
Details of compatible label dispenser types ................................................................................. 29
4. Description of the labeler ................................................................................... 30

Function and application field of the labeler ..................................................................... 30
Reference run .............................................................................................................................. 31
General overview Legi-Air 6000 ...................................................................................... 32
Figure: Legi-Air 6000 in the left and right-hand version (RH/LH) ................................................ 32
Figure: Figure: Legi-Air 6000 (RH/LH) ......................................................................................... 33
Version: 01.08.2018 Page 3 of 114 GB

Figure: Legi-Air 6000 Rear side (LH/RH) ..................................................................................... 34

Figure: Legi-Air 6000 SERO in the left and right-hand version (RH/LH) ..................................... 35
Figure: Legi-Air 6000 SERO, front view EBL2 (RH/LH) .............................................................. 36
Application modes ........................................................................................................... 37
Tamp-Blow mode ......................................................................................................................... 37
Print data management ................................................................................................... 37
Batch operation (batch processing) ............................................................................................. 37
On-demand operation (individual processing) ............................................................................. 37
(RTK) Rotating Tamp Kit (Option) ................................................................................... 37
RFID (Option) .................................................................................................................. 38
Corner wrap application with the Legi-Air 6000 SERO .................................................... 39
5. Transport ............................................................................................................. 40
Delivery ........................................................................................................................... 40
Scope of delivery.......................................................................................................................... 40
Transport and Unpacking ................................................................................................ 40
Storage conditions........................................................................................................... 43
6. Installation and initial operation ........................................................................ 44

Installation ....................................................................................................................... 45
Requirements regarding the installation location ......................................................................... 46
Positioning of the labeler .............................................................................................................. 46
Positioning of the labeler ................................................................................................. 46
Connecting the labeler .................................................................................................... 47
Overview of the connections on the labeler ..................................................................... 48
Connection to the mains voltage .................................................................................................. 49
Power connection for print module: "Printer power supply" ......................................................... 49
Connection to compressed air ..................................................................................................... 50
Connection and positioning of the product sensor ....................................................................... 51
"Display" connection .................................................................................................................... 52
"Low label sensor" connection ..................................................................................................... 52
Low Label Warning ...................................................................................................................... 52
"USB" and "Ethernet" interfaces .................................................................................................. 52
"Encoder / Analogue" connection (OPTION) ............................................................................... 53
"Bus extension" connection (OPTION) ........................................................................................ 53
"Applicator" connection ................................................................................................................ 53
"Alarm lamp" connection .............................................................................................................. 54
"Printer" connection ...................................................................................................................... 54
Print module setup (Printer) ......................................................................................................... 54
"Interface" (I/O signal interface) .................................................................................................. 55
Terminal strip ............................................................................................................................... 58
Connections of SES-IO box ......................................................................................................... 58
Insert labels and ribbon ................................................................................................... 59
Insert the ribbon (thermal transfer foil) ......................................................................................... 59
Inserting the labels ....................................................................................................................... 59
Initial commissioning ....................................................................................................... 61
7. Operation ............................................................................................................. 62
Operating the labeler ....................................................................................................... 62
Safety instruction .......................................................................................................................... 62
Switching the labeler on/off .......................................................................................................... 62
Starting labeling mode ................................................................................................................. 62
Stopping labeling mode................................................................................................................ 63

System decommissioning ................................................................................................ 64

Operating and display elements ...................................................................................... 64
Pushbutton boxes ........................................................................................................................ 64
Home and service position ........................................................................................................... 65
Operation of the display .................................................................................................. 66
Functions of the control buttons ................................................................................................... 66
Status LEDs ................................................................................................................................. 67
Program menus............................................................................................................... 67
Display of the firmware version .................................................................................................... 67
Current configuration data set ...................................................................................................... 67
Label counter ............................................................................................................................... 68
Status bar ..................................................................................................................................... 68
Menu diagram ................................................................................................................. 68
LABEL COUNTER ....................................................................................................................... 70
DISPLAY SETTING ..................................................................................................................... 71
EVENT COUNTER ...................................................................................................................... 72
CYCLE SEQUENCE .................................................................................................................... 73
LAN .............................................................................................................................................. 74
CONFIGURATION menu ................................................................................................ 75
ENTER PASSWORD: .................................................................................................................. 76
PRINT TRIGGER: ........................................................................................................................ 77
LABEL TIMEOUT: ........................................................................................................................ 79
VACUUM LEVEL: ........................................................................................................................ 79
VACUUM TIMEOUT: ................................................................................................................... 80
EXTENS. TRIGGER: (EXTENSION TRIGGER) ........................................................................ 81
EXTENS. DELAY: (EXTENSION DELAY) .................................................................................. 82
EXTENS. TIME: (EXTENSION TIME) ....................................................................................... 83
PROXIMITY T.OUT: (PROXIMITY TIMEOUT) ........................................................................... 84
BLOW TRIGGER: ........................................................................................................................ 85
BLOW DELAY: ............................................................................................................................. 86
BLOW TIME: ................................................................................................................................ 86
HOME TIMEOUT: ........................................................................................................................ 87
SYNC PULSE DELAY:................................................................................................................. 87
SYNC PULSE TIME: .................................................................................................................... 88
BARCODE RD TIME:................................................................................................................... 89
CYCLE OPTION: ......................................................................................................................... 90
EXT. SPEED (cm/s): 100 ............................................................................................................. 91
RET. SPEED (cm/s): 100 ............................................................................................................. 91
EXT. STROKE (cm): 023.0 .......................................................................................................... 91
PLATE ALIGN.(mm): 025............................................................................................................. 91
Parameter list for configuration CFG 0-3 ......................................................................... 92
PROGRAMMING ............................................................................................................ 93
DIAGNOSTICS ............................................................................................................... 93
Firmware history.............................................................................................................. 94
8. Maintenance/Repair ............................................................................................ 95
Recommended cleaning agents and lubricants ............................................................... 96
Daily repair/maintenance (after approx. 8 operating hours) ........................................................ 97
Weekly servicing/maintenance (after approx. 40 operating hours) ............................................. 98
Monthly servicing/maintenance (after approx. 200 operating hours) ........................................... 99
Half-yearly servicing/maintenance (after approx. 1000 operating hours) .................................. 100
Annual servicing/maintenance (after approx. 2000 operating hours) ........................................ 100
Spare parts ................................................................................................................... 101
Wiring and pneumatic plans .......................................................................................... 101
Cleaning quick overview ............................................................................................................ 101
9. Troubleshooting ................................................................................................ 103

Mechanical errors .......................................................................................................... 103

Error messages via display ........................................................................................... 107
Error reset .................................................................................................................................. 107
Status message via display ........................................................................................... 111
10. Index ................................................................................................................... 113

Keywords from A to Z................................................................................................................. 113

Chapter 1 General 40045925 BTA Legi-Air 6000 V2
1. General
Overview
Congratulations, you have decided to purchase a high-quality labeling system. Our aim is
to ensure that you can fully utilize this system to your complete satisfaction for many years
to come. To ensure this, we strongly recommend that you have the installation (refer to
the notice on page 45) carried out by one of our experienced specialists. Contact our ser-
vice hotline (see page 8), we are available to you 24 hours a day from Monday - Friday.
Limitation of liability
All information and instructions in this manual have been compiled taking into account the
applicable standards and rules, the latest technological developments as well as our many
years of know-how and experience.
The manufacturer shall not accept any liability for damages due to:
 Non-observance of the operating instructions
 Improper use
 Use of untrained personnel
 Non-approved modifications to the system
 Use of spare parts that have not been approved by the manufacturer
The obligations agreed in the delivery contract, the general terms and conditions of busi-
ness as well as the manufacturer's delivery conditions and the statutory regulations appli-
cable at the time of contract conclusion will apply. We reserve the right to technical
changes and further development in order to improve the performance characteristics.
Warranty conditions
The warranty conditions comply with the general terms and conditions of business of
Bluhm Systeme GmbH valid at the time of purchase.
Copyright
This documentation or parts of the document may only be copied, photocopied, repro-
duced or translated into other languages for personal use. A reproduction for disclosure to
third parties is not permitted without the prior written consent from Weber Marking Sys-
tems GmbH.
Purpose and scope of the operating instructions

These operating instructions are designed to introduce the system and to facilitate its in-
tended use.
They contains important instructions for the user on how to use the system safely and ap-
propriately. Following these instructions helps to avoid danger, reduce repair costs and
down time, and also increases the reliability and service life of the machine.
The operating instructions are valid for the system referred to in the title with the type
number specified.

The operating instructions must be accessible at all times where the system is being used
and must be read and observed accordingly by persons who are tasked with working on
the system.
Printing errors, mistakes and changes in accordance with the latest technological
developments are reserved. For clarification, illustrations can be shown without protection
devices.
Notes on using the operating instructions

The following you will find a detailed explanation of the writing and representation styles
used in this Service Manual.
 Buttons and switches that need to be actuated are shown in square brackets.
Example: Press the [Start] button to apply the change ...
 Work sequences that must be followed are numbered.

Step Approach
1 Disconnect the mains plug...
 Special information is written in bold and/or with a grey background.

This is an example of special information!
 All illustrations (Fig.) are numbered consecutively for each chapter. This means
that a reference to "Fig. 2-1" is equivalent to the 1. Illustration in Chapter 2.
 Illustrations are often reduced to show the essentials, and can therefore differ
from the original. The absence of covers or protective devices in illustrations is
therefore only performed to promote a better understanding.
 Illustrations are sometimes confined to the depiction of a single version (e.g. only
RH or only LH...), especially when the information content can be appropriately
applied to other versions.
 Messages which are shown in a *²display, will appear in a box:
*² only with an appropriately equipped system

Service Hotline
The technical Service Hotline is available 24 hours a day from Monday to Friday. In case
of emergencies, a shipment of parts is possible until approx 10:00 PM.
Tel.: +49 (0)2224 - 7708 - 440
Fax: +49 (0)2224 - 7708 - 21
E-mail: hotline-ed@bluhmsysteme.com
You will need to have the following information available when you call the hotline in the
event of the labeler malfunctioning:
 Detailed description of the fault.

 All information from the nameplate of the labeler.
 Did the error occur for the first time after the following work step?
 After inserting a new label / colour ribbon roll.
 After making changes to the system configuration.
 All information about the state of the PLC signals, in case of a failure of the print-
application-cycle.
Before contacting our hotline, we kindly ask you to check whether the operating instruc-
tions ("Troubleshooting" chapter) already provide the appropriate troubleshooting instruc-
tions.
We aim to maintain the highest degree of availability of our hotline for our customers.
Please understand that our hotline may ask you to apply the written information provided
in the operating instructions.

Explanation of the technical terms
Technical term Explanation

Air Assist A jet of air which presses the label against the bottom of the
tamp / Blow-Box during the feed, until it is held by the
vacuum.
(Application) stroke Distance travelled by the tamp when extending in the direc-
tion of the product
Adhesive strings Leaked adhesive at the label edge can cause the label to
adhere to the carrier paper. The printed label remains stuck
to the carrier paper and cannot be pushed onto the tamp.
Air assist tube The Air Assist Tube directs the support air through one or
more holes to the bottom of the label. It is installed in the area
of the peel bar and is adjustable.
Application cycle Complete operational sequence of the labeler (e.g. label
printing (if applicable) and peeling off (if applicable), label
transfer to the applicator up to the labeling of the product).
Application mode See explanations: Tamp On, Tamp Blow, Blow On
Applicator Term for label applicators or mechanical means that position
the tamp.
Automatic operation See labeling mode
Bad Tag "Bad Tag" refers to a faulty transponder on an RFID label.

This tag could not be read and/or written to. (See also Tag).
Belt conveyor Conveyor for product transport.

Blow-on Contact-free application mode, during which the tamp takes
over the printed label through vacuum, and "blows" it onto the
product without repositioning the tamp.
Blow-on/blow-off air When the label is applied, air is pressed towards the label
through holes in the tamp pad (for the Blow-Box via hose
(Air Blast) nozzles), which enables contact-free application onto the
product.
Configuration mode Mode, during which parameters of the applicator configura-

tion can be adjusted in the display
Contrast Difference in the brightness of the light and dark areas of a
print
Conveying system Complete system, consisting of the belt conveyor and its
controller
CT Abbreviation for conveying system (see above)
Cycle Sequence of the labeling process, from product detection,
through product labeling, all the way up to the tamp reaching
its home position.
Dancer arm Arm that keeps the label liner under tension through spring
force
Default See Factory setting
Display Display panel where the status information is shown to the

operator.


EC Declaration of This labeler is partly completed machinery. A compliance with
Conformity EU directives is certified by the installation declaration for this
machine (included in the scope of delivery).
Edge detection The edge (front or rear) of a product or a label is used by the
sensor for the detection of the product or respectively the
label gap.
Factory setting Includes all basic factory settings of the system which, how-
ever, may differ from the state after commissioning the sys-
tem. Software parameters are reset by resetting to the factory
settings (default values) and the previously adjusted values
will be lost.
Feed (label feed) The [Feed] button transports the label.
Home Position Basic position of the tamp at the peel bar
Home position sensor Sensor to acquire the end position, when the tamp is in home
position
Hotline Customer support for quick diagnosis over the phone
Applicator Unit for the application of labels
Low label sensor An optical sensor (diffuse reflection light scanner) which is
used to alert about a (preset) minimum label roll diameter
Low label pre-warning An optical sensor (diffuse reflection light scanner) which is
(Label Out) used to detect the label end
Label feed The feeding of a label. During the printing process or if the
[feed] button is actuated, the drive motor of the print module
will be activated, and label liner transport started (dancer arm
releases the unwinder brake). if applicable, the fed label is
printed within the print module and detached from the carrier
paper at the peel bar
Label gap sensor See Label sensor
Label Gap Spacing between two labels on the label liner. The gap is
detected by the applicator via a (label) sensor
Label sensor An optical sensor which detects the gap between labels
Label size Specifies the label format: Width x length (in the travel direc-
tion of the label liner), and is measured in millimetres [mm]
Label web Silicon-coated carrier with individual labels stuck on it
Labeler Application system for the automatic application of labels

Labeling mode Corresponds to the automatic operation mode. The labeler is
ready to print and apply labels
Leading Edge The leading edge of a product/label is used to start a process
(also refer to edge detection)
LED Light-emitting diode
Maintenance unit Unit consisting of:
(FR group)  Compressed air regulator pressure gauge to indicate
the amount of compressed air (in bar)
 Quick-lock valve
 Water separator for manually draining any conden-
sate that may be present


Peel bar Metal edge over which the label is peeled off. When labeling
with a print module, the peel bar will be located there under
the print head
Photocell Product detector. The sensor detects the product to be la-
belled and trips the trigger signal. See Trigger signal
PLC Programmable logic controller
Pneumatics Uses compressed air as an energy source to create move-
ments and currents.
Potentiometer Alterable resistor (controller) for analogue control of settings
on the labeler (e.g. the time behaviour of the tamp movement
depending on the rotational position of the potentiometer)
Pressure gauge See Maintenance unit
Print job Label layout, consisting of images, bar codes... print data incl.
control commands (print application, volume, contrast,
speed...), which will be sent to the printer via the data inter-
face.
Printhead Printhead of the print module. Tiny heating elements (dots) in

the print head generate heat. This heat causes ...
 Direct thermal: ...a colour change in the print medium
 Thermal transfer: ...detachment and transfer of colour
from the thermal transfer ribbon onto the print medium
Product delay An adjustable delay time from the product detection up to the
start of the application cycle
Product sensor A sensor to detect the product. Optical sensors are most
(Product detector) commonly used (photocells, light barriers, reflex sensors)
Reset Command to reset the software systems to default values

which is usually activated by a key combination
Rewinder Holder (usually for a 3 inch cardboard core) to rewind the

label liner. The rewinder spools the carrier paper that is
returned from the print module. It is controlled by means of a
dancer arm (see dancer arm). Rewinders have a motorized
drive.
RFID This acronym stands for Radio Frequency Identification

(radio detection). With the help of this technology it is possi-
ble to label the products with so-called smart labels (see
RFID label) to provide effective tracking.
RFID label The RFID tag, also referred to as Smart-Label, is a special
label which is equipped with a transponder that is able to
send or receive data via radio signal. The identification of
such labelled products is possible via antennas without
contact.
Sensor for variable stroke A proximity sensor that is mounted on the tamp and recog-
nizes the product. If a product is detected, the label is blown
on / applied.
Spindle (Mandrel) A powered axle with a fixture for the attachment of the label
liner. The spindle is used for winding the carrier.
Tamp Unit that picks the label through vacuum, transports it to the
product and applies it there.


Tamp (vacuum/blow tamp) Drilled plate of the tamp, to which the peeled-off label is
passed
Tamp movement time Duration of the tamp movement (extension and retraction)
during the labeling cycle.
Tamp-blow Contact-free application mode, during which the tamp takes
over the printed label through vacuum, transports it to the
product and blows it onto the product
Tamp-on Application mode, where the tamp takes over the printed
label through vacuum, transports it to the product, and press-
es it onto the product
Touch screen Touch-controlled screen, display, monitor ...
Trailing Edge The trailing edge of a product/label is used to start a process
(also refer to edge detection)
Transponder The transponder is part of an RFID label and is also referred
to as a tag. It consists of a micro-chip and an antenna.
This chip is able to store data that is read and depending on
the version, also written via radio waves. The antenna of the
transponder is used as a transmitting and receiving antenna.
At the same time, it provides the required power to the chip
by converting the energy in the electric field of the RFID
transmitter antenna into electricity.
Trigger signal The signal from a sensor or a PLC that is used to activate an
application process.
Unwinder Holder for the label roll (usually for a 3 inch cardboard core).
The unwinder enables the label roll to unwind smoothly
without jerking and is metered by a roller brake (see also
dancer arm). Unwinders can also be equipped with a motor
drive.
VAC AC voltage.
Vacuum generator A unit that uses compressed air to generate a vacuum
(Venturi) (negative pressure).
VDC DC voltage.
Void signal Name of the signal generated by the print module, which is
sent internally to the applicator controller upon detection of a
bad tag.
Water separator See Maintenance unit.
Web Label liner, consisting of a siliconized backing tape and the
attached labels

Chapter 2 Safety regulations 40045925 BTA Legi-Air 6000 V2
2. Safety regulations
Behaviour in case of emergency

The operating personnel must be familiar with handling and the locations of safety, accident
reporting, first-aid and rescue equipment.
What to do in case of an emergency?

 If people, body parts or objects are jammed in the moving parts of the labeler, imme-
diately disconnect the labeler from the compressed air and power supply.
 Initiate all necessary assistance for injured persons immediately. It is essential to ob-
serve all applicable safety regulations to avert further personal injury.
 Call for medical help for the injured persons.
 Eliminate all accident causes.
General safety regulations
Safety instructions provide information in the form of texts and symbols to warn against
and avert danger, in order to avoid personal injury and damage to property.
Safety instructions are preceded by signal words to express the extent of the risk.
Safety instructions can be attached directly to the labeler or be found in the associated
documentation.
Meaning of the risk levels
This symbol indicates hazardous situations, which will lead to

serious injuries or death. All safety instructions must be observed
to avoid personal injury.
This symbol indicates hazardous situations, which can lead to
serious injuries or death. All safety instructions must be observed
medium or minor injuries. All safety instructions must be observed
property damage. All safety instructions must be observed to avoid
property damage.

Intended use
The operation reliability of the labeler is only guaranteed when used as intended.
Intended use occurs when …
 the labeler is exclusively used for automatic labeling of moving or stationary

products.
 manual interventions are only made after the labeler has been stopped.
 the labeler is used for the specified products which have been agreed upon with
the customer and with the labels which have also been specified and agreed up-
on. The products and labels must correspond to the specifications *documented
and agreed upon between the machine manufacturer and the customer.
* "Documented specifications" are usually set out in the SAD (System Application Description) which are provided to the
customer with the order confirmation.
the labeler is used in a non-explosive environment. (No EX protection suitability!).

 the labeler does not come into direct contact with foodstuffs.
 the labeler is not used for outdoor applications.
 the labeler is used in a wet environment with an automatic slide plate at the tamp
outlet.
 the labeler is operated with additional ventilation measures in the stainless steel
protective enclosure for use in aggressive air (e.g. salty air or similar).
 the labeler is operated with additional ventilation measures in the protective
enclosure for use in a dusty environment with floating particles.
 the labeler is only operated within its specific performance data (see technical
specifications).
 the labeler is only used in the EU (European Union) and only in the industrial
sector.
 the working conditions and instructions prescribed these operating instructions
are complied with.
 Faults on the labeler which could affect the safety must be reported immediately
and also immediately eliminated by qualified and trained personnel.
 maintenance is carried out properly.
 the labeler is only operated in perfect condition.
 protection devices are not bypassed or deactivated.
 no arbitrary changes are made to the machine.
 all people who work on the labeler, use or manage it must have read and under-
stood the operating instructions (see also "Authorised personnel", page 21).
Any use of the labeler which does not comply with one of these points is considered as
improper and can lead to serious property damage and personal injury.

Reasonably foreseeable misuse
A different use other than specified under "intended use", or any other additional use will
be considered as improper use!
Damage caused by improper use
 will be the sole responsibility of the operator,
 and the manufacturer will not assume any liability.
Certain risks can emerge in case of an improper use!
Improper use includes:

 operation in an explosive atmosphere
 the labeler coming into contact with food ...
Conversions and modification of the labeling system

Any liability and warranty of the manufacturer will be void if unauthorized modifications
and alterations are made to the machine! This also applies to interventions and program
changes to the programmable control system, as well as parameter changes to control
devices, insofar as these are not described in these operating instructions.
The electromagnetic behaviour of the machine can be affected by changes or modifica-
tions of any kind.
So refrain from making changes or adding to the machine without consulting and obtain-
ing written consent from the manufacturer.

Sources of danger at the labeler

Possible sources of danger can only be shown here as examples. You can find more details
in the chapter of the same name in the operating instructions of the appropriate labeler.
Fig. 2-1: Examples of sources of danger at the labeler
The following dangers can emanate from the labelers:

 danger of crushing and cutting on the tamp and linear unit especially in the area
of the…
o sensor flag (home position),
o peel bar print module,
o base plate and fixed components,
o products (transport line).
 danger of crushing and cutting on the tamp and rotating arm especially in the
area of the…
o home sensor (home position),
o peel bar print module,
o base plate and fixed components,
o products (transport line).
 Risk of burns from the servo drive
The forces which develop on the tamp are not limited. Also the movement speeds of the
tamp are extremely high, so that a quick dodging is nearly impossible.
These dangers represent a potential risk for injuries to people which can be classified as
high (usually irreversible).
That is why special protection measures (e.g. guard, protective enclosure, light curtains...)
are required before the labeler can be operated.
The servo drive of the tamp can overheat severely depending on the utilization, and cause
burns when touched.

Warning notices on the labeler

Special sources of danger on the labeler are marked with yellow stickers. The pictograms
used indicate the dangers:
Danger
Danger to life from electrical current
Risk of crushing
Entanglement hazard
Danger from hot surfaces
Danger from strong light beam radiation
Observe the operating instructions
Safety instructions
Danger through direct or indirect contact with live parts.
DANGER TO LIFE!
Personnel can be killed by coming into contact with voltage-
carrying parts.
̶ Before working on electrical equipment, switch the circuit
breaker to the "0" position, and secure it against accidental re-
activation. If possible, disconnect from the mains.
̶ Work on the switching cabinet or electrical equipment may only
be performed by skilled electricians and only with tested insu-
lated tools.
̶ Regularly check the electrical equipment of the labeler (see
Chapter "Maintenance/servicing").
̶ Immediately eliminate loose connections or damaged cables.
̶ Always keep the switching cabinet closed.

Danger from highly flammable label stock.
DANGER OF FIRE!
Foil and label stock are highly flammable. Risk of injury from fire
and smoke.
̶ Keep away from ignition sources and open flames.
Hazards from moving parts.
RISK OF INJURY!
Entanglement and risk of being crushed through pneumatically
or mechanically-powered labeler components.
Movements or rotations can start suddenly and abruptly in label-
ing mode.
̶ Do not reach into, towards or between moving parts.
Health hazard due to improper handling of lubricants and

cleaning agents.
HEALTH HAZARD!
Improper handling can lead to health hazards.
̶ It is necessary to observe and comply with the respective
product information on the applicable safety data sheets from
the manufacturers of the utilized lubricants and cleaning
agents, as well as their safety and disposal regulations.
Danger of breakage during operation.
RISK OF INJURY!
Danger of material fatigue due to the application of additional
weights (label rolls, tool, etc.) on the system.
̶ Do not fasten or deposit additional weights to the system.
Danger of residual energy in pneumatic components.
RISK OF INJURY!
Whipping compressed air hoses, discharged parts or uncon-
trolled moving parts can cause injuries.
̶ Before creating the compressed air connection, check all
pneumatic connections for tightness and firmly attach them if
necessary.
̶ The pneumatic system slated for maintenance must be vent-
ed before the dismantling of the pneumatic components is
performed.

Danger of breakage during operation.
RISK OF INJURY!
Danger of material fatigue due to the application of additional
weights (label rolls, tool, etc.) on the system.
̶ Do not fasten or deposit additional weights to the system.
Danger from hot surfaces.
RISK OF BURNS!
High temperatures can develop on the servo motor (above 80°C).
̶ Allow the motor to cool down before performing any work
Risk of tripping through connection cables.
RISK OF INJURY!
Connecting cables for power, compressed air, as well as data
and signal lines are potential tripping hazards and can cause
serious injuries.
̶ Relieve the stress from the connecting cables and route in
such a manner that no danger zones can develop.
There is a risk of injury on edges and corners.
RISK OF INJURY!
Sharp edges and sharp corners can cause abrasions and cuts to
the skin. Always keep the work area clean.
̶ Caution when working in the vicinity of sharp edges and sharp
corners. Remove any items which are not required.
̶ In case of doubt wear protective gloves.
Remaining risks
The labeler is designed such that you can safely operate it. Hazards which cannot be
avoided for constructions reasons are avoided as far as possible through protection de-
vices. However, a certain residual risk will always remain! Knowing about the residual
risks of the system will help you structure your work even more safely, thus avoiding acci-
dents. Please also observe the special safety instructions in the respective chapters, in
order to avoid the hazards.

Disposal
This labeler complies with the RoHS II EU directive 2011/65/EC,

under observance of the therein contained usage bans and
pollution avoidance provisions.
Obligations of the operator

These operating instructions are a component of the machine, and must always be kept at hand.
In order to ensure safe operation of the labeling machine, the operators shall have the obliga-
tion to....
 make sure that the safety of people working on the labeler is always guaranteed.
 that technical data and information regarding the assembly, connection, ambient
and operating conditions is consistently respected.
 ensure the compliance with the labeler-specific safety regulations.
 ensure that the use of personal protective equipment is observed.
 ensure that signs or danger notices are replaced in case of damage or loss.
 ensure that persons who need to be instructed or trainees are under the constant
supervision of an experienced person.
 ensure that all work on the electrical equipment is only carried out by qualified
electricians.
 ensure that all faults on the system are eliminated by trained personnel, or by
technicians from the Bluhm-Weber-Group.
 ensure that the technical personnel is properly trained to operate the integrated
controller before parameter settings are carried out.
If you don't understand any part of these operating instructions, please contact
your Bluhm-Weber contact person immediately.

Approved persons
In these operating instructions, approved persons refer to the following persons:
Operators are persons who...
 were instructed on the operation of the machine
 have reached the legally required minimum age limit.
 have read and understood the operating instructions.
Operators are authorized to...
 start or stop labeling operation.
 replace the label rolls.
 perform the daily necessary cleaning work on the machine in accordance with
Chapter Repair/maintenance.
Technical personnel are operators who...
 have completed a technical training (electrical technician, mechanic).
 have successfully completed a training course of the Bluhm-Weber Group.
Technical personnel is entitled to...
 perform repair and maintenance work on the machine and its components, ac-
cording to their respective professional qualifications.
Personal protective equipment

When working on the machine, the following protective equipment must be worn:
SAFETY SHOES
̶ Must be worn to protect against slipping and falling parts.
PROTECTIVE WORK WEAR

Tight-fitting clothing with tight sleeves and a low tensile strength, with-
out protruding parts
̶ If necessary, wear a hair-net
̶ Do not wear jewellery or watches
SAFETY GLASSES
̶ These must be worn as a protection against cleaning agent splash-
es and airborne parts.
PROTECTIVE GLOVES
̶ Help protect against sharp objects.
Wear personal protective equipment for Protective

Protective Safety Safety
the following activities. hand
work wear shoes glasses
shoes
Machine transport. x x x
Machine set-up and connection. x x
Maintenance work. x x x
The documentation from the manufacturers of the
individual machine components must be observed!

Protection device
Only operate the labeler if all safety and protective devices are completely available and
fully functional. Check the protective devices for their functionality:
 during the initial commissioning,
 during the regular routine examination,
 after the exchange of safety-related components and parts.
If defects occur on the protective devices during the operation, immediately stop the
labeler and eliminate the defects! Do not change or remove any protective devices.
To not disable any protective devices by performing changes. Safety devices may only be
removed for maintenance and repair purposes if the labeler is an standstill and with an in-
stalled protection against startup (for example, a padlock on the main switch).
If subcomponents are supplied, the safety equipment must be properly installed by the
operator. Danger points can develop at the transition areas of the customer-side convey-
ing systems. Appropriate protection measures must be implemented in these cases.
Machine cover
The fixed and bolted on machine covers protect the user against mechanical risks.
Separating and non-separating protection devices

The Legi-Air 6000 requires an additional protection device for operation (refer to the as-
sembly instructions supplied for the labeler). Only through the additional protective
measures will the labeler become a "complete machine" pursuant to the Machinery Di-
rective 2006/42/EC.
If such a labeler is installed in a non-access-secured area, appropriate protective

measures must be implemented to prevent access to the hazardous area. If the protective
measure is not a component of the scope of delivery, the design of the protective measure
will be the responsibility of the operator or user.

Example of access protection according to EN ISO 13857 (see Fig. 2-2). The General
Guidelines for the Safety of Machinery (2006/42/EC) must be observed for the design of
the safety barrier.
Fig. 2-2: Example of safety barrier

Emergency stop function

An integrated emergency stop relay (PL = e, according to EN 13849) forms a safety circuit
to which various safety components can be connected. Depending on the labeler's scope
of delivery (cf. Fig. 2-3), these are commonly light curtains (4) or safety door switches (2)
that monitor access to the danger zone. It is also possible to integrate [emergency stop]
pushbuttons (3) into the safety circuit.
A relay contact to the query the operating status (see Monitoring) can also be used by the
customer. For details, please refer to the wiring diagram (in the scope of delivery).
Activation of the emergency stop circuit

Upon entering the light curtain, or opening the access door of the safety barrier or press-
ing the red [emergency stop] pushbutton, the emergency stop relay will interrupt the
emergency stop circuit. The drive circuit will be de-energized, causing the brake on the
servo-drive to be activated. The tamp will stop immediately and remain in that position.
The labeler will switch to fault "Stand-by", and will therefore not be ready for operation
(see below Monitoring).
Restart or error acknowledgement, see Chapter Troubleshooting (page 107).
Fig. 2-3: Examples of safety equipment
No. Designations
1 REMOTE PUSHBUTTON BOX
2 DOOR CONTACT SWITCH (OPTIONAL)
3 EMERGENCY STOP PUSHBUTTON (OPTIONAL)
4 LIGHT CURTAIN (OPTIONAL)

Control of applicator brake

The applicator brake is located directly on the servo
drive. During normal operation, this is unlocked
electrically. If the emergency stop circuit was activat-
ed (see above), the control voltage of the brake lock
will also drop. The brake is now active and will stop
the tamp.
Fig. 2-4: Example of pushbutton box
[brake release] Using the [Release brake] button (see left Fig. 2-4),
the locking can be opened and the application stroke
[Brake release] button can be shifted manually.
Monitoring
There is a potential-free relay output available to monitor the operating status, which will
be closed when the labeler is started. For details, please refer to the wiring diagram (in the
scope of delivery).
Workplaces for operating and technical personnel

The labeler is an automated system and does not require operation in labeling mode.
In (fault-free) labeling mode, people are only allowed to stay in the safety zone,
meaning the area secured by the protection measures.
During troubleshooting (e.g. label removal...), maintenance work and repairs, operation
from all sides of the system is possible, as long as this does not expose the person to any
other hazards (conveying systems...).
When refilling consumable materials, operation is exclusively intended to be carried out by
one person.
Interventions are only permitted when the labeling machine has been stopped.
After the troubleshooting and/or restarting the labeler, the operator must immedi-
ately evacuate the danger zone and move into the area secured by protection
measures.

Chapter 3 Technical Specifications 40045925 BTA Legi-Air 6000 V2
3. Technical Specifications
Supplementary or divergent information on the nameplate of the machine must also be

taken into consideration and must always be given priority.
Power connection: 85-264 VAC / 47-63 Hz
Power consumption: max. 1200 W (incl. print module (max. 450 W))
Ambient temperature: 10 - 35°C
Ambient conditions: 20-90 % relative humidity (non-condensing)
Ingress Protection: IP 20
Compressed air connec- 5 - 7 bar (according to DIN ISO 8573-1)

tion:
Compressed air quality according to DIN EN ISO 8573-1
- Remaining oil content (quality class 5) = 25 mg/m³
- Residual dust (quality grade 3) = 5 µm ; 5 mg/m³
- Residual water (quality grade 4) = 6 g/m³ ; +3°C
Max. air consumption: up to 200 Nl/min (under extreme conditions)

(0.3 - 3 litres per application cycle)
Weight: approx. 75 kg (without label roll)
Label rolls, Ø =350 mm (corresponds to 450 running metres)

outside diameter: core = 76 mm (3")
Information on further dimensions (SES linear applicator)
Dimensions: (H x W x D in mm) 1350 x 920 x 675
Maximum usable applica-

tion stroke length: 640 mm
(linear stroke)
Tamp: (W x H): max. 150 x 210 mm / min. 100 x 210
Label size: max. 160 x 210 mm / min. 40 x 30 mm
Information on further dimensions (SERO rotating applicator)
Dimensions: (H x W x D in mm) 620 x 1241 x 681
Translation ratio:
1: 20
(Servo rotating applicator)
Tamp: (W x H): 120 x 160
Label size: max. 120 x 160 mm / min. 40 x 30 mm

Performance data (SES linear applicator)
Up to 80 and max. 150 labels/min. (depending on the label

Application cycle rate: size, stroke length,...)
Dispensing spacing: 0 - 50 mm (depending on the size of the label)
Application accuracy:
+/-0.8 mm on the stopped product
at a dispensing spacing below 50% of +/-3.0 mm during the pass
the smallest label side
Performance data (SERO rotating applicator)
Application speed: 3m/s
Dispensing angle: 45-200°
Application accuracy:
+/- 1 mm on the stopped product
at a dispensing spacing below 50% of
the smallest label side
Information about operating elements
HMI LCDisplay 2 lines, each with 20 characters

(background lighting)
HMI control buttons 5 buttons ([START], [STOP], [Enter], [>] and [<])
Remote button box [Start], [Off]
Pushbutton box [Brake release]
Optional (not required for operation)

HMI Display (OLED) Graphic OLED HMI display, 2 buttons and 1 [rotary press]
switch
Noise level
The measurements at a distance of 1 m from the machine surface and 1.60 m above the
floor show following noise emissions:
A sound pressure level 72 dB
C sound pressure level 80 dB

Details of compatible print module types

Possible print module types that can be installed in the Legi-Air 6000:
Manufacturer Type designation / print width / print resolution

Novexx DPM 4 / 106 mm 300 dpi
DPM 5 / 127 mm 300 dpi
DPM 6 / 160 mm 300 dpi
CAB PX4 / 104 or 105.6 mm 200 / 300 / 600 dpi
PX5 / 104 or 108.4 mm 200 / 300 dpi
PX6 / 168 or 162 mm 200 / 300 dpi
DATAMAX A-Class MK II / 105 mm 200 / 300/ 400 / 600 dpi
A-Class MK II / 162 mm 300 dpi
A-Class MK II / 168 mm 200 dpi
Sato S84-ex / 112 mm 200 / 300 / 600 dpi
S86-ex / 152 mm 200 / 300 / 600 dpi
Zebra ZE 500 / 104 mm 200 / 300 dpi
ZE 500 / 168 mm 200 / 300 dpi
Details of compatible label dispenser types

Possible label dispenser types that can be installed in the Legi-Air 6000:
Manufacturer Type designation / media width / feed speed

Weber LDE / 177 mm / 3000 mm/min
LDM / 177 mm / 3000 mm/min

Chapter 4 Description of the labeler 40045925 BTA Legi-Air 6000 V2
4. Description of the labeler
Function and application field of the labeler
Application field
The Legi-Air 6000 is a high performance labeler for the automatic labeling of different
products. The label contains customer-specific data (for example: EAN128 bar code, date,
time/date, logo...), which is printed in-process with an integrated print module.
Applicator concepts
The Legi-Air 6000 series is characterised by its special applicators with a powerful servo
drive and advanced materials (carbon, 3D print head). On the Servo Electrical Slide
(SES), the tamp is moved in a linear fashion on a toothed belt axis through an electric
servo drive. With the Servo Rotation (SERO) Applicator, the curved applicator arm is con-
nected to the geared shaft of the servo drive. The lightweight design and the drive concept
enable high application speeds.
Control of the labeler

The Legi-Air 6000 series consists of a labeler with an intelligent control system, a print
module and a servo applicator with its own controller. All three components can be pa-
rameterised via the display, whereby the labeler coordinates all operations between the
components.
In particular, on the Legi-Air 6000, the controller "regards" the servo applicator as a
pneumatic applicator. This is important for parameterisation via the HMI display, as a dis-
tinction is made here between the settings of the electrical and pneumatic applicators.
The controller of the servo drive can be parameterized through a dedicated HMI (option-
al). However, changes to the factory parameters are only necessary in special cases, and
require specific expertise.
Function and operation

The Legi-Air 6000 prints and applies labels to stationary or moving products. To perform
precise and contact-free labeling, the distance to the product in the extension movement
is acquired through the sensors of the tamp. The label will be blown off as of an adjustable
distance, and the tamp will move back to the home position.
The linear stroke can be prepositioned for time-critical applications. Optional distance
measurement records the distance to the product as an absolute value. The tamp moves
to this value (+/- a settable offset) and waits. As soon as the conveyed product has
reached its labeling position, the label is blown off and the cycle for the next product can
begin.
Printing labels
The Legi-Air 6000 can be operated in combination with various print modules. An over-
view of the possible combinations is listed under "Technical data". An operator's manual
(quick reference guide) for the print module used is included in the scope of the system
delivery.

Service position
If the Legi-Air 6000 SES is stopped regularly via the remote pushbutton box, the tamp will
move back into its service position. This is located a few cm above the home position, and
provides an easy access to the print module for servicing work etc.
Reference run
During the startup or re-start (after a failure, etc.), the applicator will perform a short refer-
ence movement to reinitialize its position.

General overview Legi-Air 6000

Figure: Legi-Air 6000 in the left and right-hand version (RH/LH)
Fig. 4-1: Legi-Air 6000 RH/LH in front view
No. Designations
1 CARRYING STRAP
2 HMI
3 LOW LABEL SENSOR

4 UNWINDER
5 REWINDER
6 DANCER ARM (UNWINDER)
7 DEFLECTION ROLLER
8 PRINT MODULE
9 AIR ASSIST
10 SENSOR (VARIABLE STROKE) 2 VARIANTS
11 TAMP
12 REMOTE PUSHBUTTON UNIT
13 SERVO DRIVE
14 [BRAKE RELEASE] BUTTON
15 HSM CONTROLLER
16 CARBON TUBE
17 LINEAR AXIS
18 HOME POSITION SENSOR

Figure: Figure: Legi-Air 6000 (RH/LH)
Fig. 4-2: Legi-Air 6000 in plan view
No. Designations
1 REWINDER-UNWINDER ENCLOSURE (WITH THE ELECTRICAL CONNECTIONS)
2 U-ARM
3 CONTROLLER BOX UNIVERSAL
4 HSM CONTROLLER
5 SERVO DRIVE
6 PUSHBUTTON BOX [BRAKE RELEASE]
7 TOOTHED BELT AXIS
8 ENERGY CHAIN
9 TAMP
10 PRINT MODULE
11 UNWINDER

Figure: Legi-Air 6000 Rear side (LH/RH)
Fig. 4-3: Legi-Air 6000 RH and LH with rear side view
No. Designations
2 UNWINDER DISK
3 TOOTHED BELT AXIS
4 ENERGY CHAIN
6 HSM CONTROLLER
7 SERVO DRIVE BRAKE
8 U-ARM
9 AIR ASSIST CONTROLLER
11 COMPRESSED AIR CONNECTION (KS4-CK) + WATER SEPARATOR

Figure: Legi-Air 6000 SERO in the left and right-hand version (RH/LH)
Fig. 4-4: Legi-Air 6000 SERO RH/LH in plan view EBL2
No. Designations
1 CARRYING STRAP
2 HMI
3 LOW LABEL SENSOR

4 UNWINDER
5 REWINDER
7 DEFLECTION ROLLER
8 PRINT MODULE
9 AIR ASSIST
10 CLAMPING SPRING
11 TAMP
13 SERVO DRIVE SHAFT

14 [BRAKE RELEASE] BUTTON
15 CARBON SWING ARM

Figure: Legi-Air 6000 SERO, front view EBL2 (RH/LH)
Fig. 4-5: Legi-Air 6000 RH/LH in plan view EBL2
No. Designations
2 U-ARM
3 STAINLESS STEEL ENCLOSURE
4 SES I/O BOX
5 SERVO DRIVE
7 HOME POSITION SENSOR
8 SWING ARM
9 TAMP
10 PRINT MODULE
11 UNWINDER
13 PUSHBUTTON BOX [BRAKE RELEASE]

Application modes
Tamp-Blow mode
The printed label is moved to the proximity of the product on a vacuum stamp prior to the
application, and then blown-off onto the product.
The Tamp-blow mode is often used because it labels the product in a contact-free man-
ner, and thus represents a low-wear operation method.
Other application modes (which can be parameterized) are untypical for the Legi-Air 6000
and will therefore not be described any further.
Print data management

Print data that is sent to the labeler must be provided in different ways according to the
requirements:
Batch operation (batch processing)

Through this, a print job for a larger number of matching labels is transmitted to the print
module. All products will receive labels with identical print data.
On-demand operation (individual processing)

Synchronized with the product transport, the Legi-Air 6000 receives a data set for one la-
bel before the product arrives.
A wrongly transferred print job or a data set which should no longer be used after a mal-
function, can be deleted using a software command. However, this delete command must
be sent off via the data interface before the transmission of the next job.
(RTK) Rotating Tamp Kit (Option)

If the labeler with linear stroke possesses a rotating tamp (RTK),
then the label can be rotated through 90° after printing. The
"normal" application cycle then follows.
The 90° rotation is performed using a pneumatic cylinder. The
rotation is controlled via an external signal (see X37 connection
of the SES-IO box, page 58).

RFID (Option)
Fault or damage to the labeler due to overloading of the

reject plate.
Rejected RFID labels must be regularly removed from the reject
plate:
̶ After acknowledging the fault E17 (maximum capacity of
rejected RFID labels reached)
̶ Before each restart (after 2 x [Stop] button)
The Legi-Air 6000 is RFID ready, i.e. in combination with an RFID print module, it allows
the automatic printing and application of RFID labels.
Depending on the accessories, the function expansion of the Legi-Air is first limited to in-
ternal communication with the RFID print module (no directly recognisable differences to
the standard Legi-Air 6000).
Together with an optional reject plate, correct parameterisation (see cycle options, see
page 89) will produce an expanded scope of functions.
Fig. 4-6: Reject plate (view of the underside of the system)
No. Designations
1 RFID LABEL
2 REJECT PLATE
Unreadable or non-writable transponders must be rejected. The RFID label is checked for
this before being written by the print module. If a faulty RFID label was determined (Void
signal, print module), the label is pushed onto the tamp and rejected.
To do this, the reject plate swings in front of the tamp. The faulty RFID label is applied di-
rectly to the reject plate without a movement by the tamp.

Corner wrap application with the Legi-Air 6000 SERO

Typically, a Legi-Air 6000 SERO (90° applicator) is used to label products wrapped
around front corners.
The labeler must be positioned in

such a way to the product that a part
of the label overhangs on the front
side of the product.
After the application operation, the

overhanging section of the label must
be pressed onto the side of the pass-
ing product.
This is done using an optional pres-

sure applicator (see Fig. 4-7) or
brush.
The label is applied around the cor-

ner and, when the product passes
the labeler, is pushed on at the side.
Fig. 4-7: Legi-Air 6000 Rotating tamp with deflection roller
No. Designations
1 LABELER (LEGI-AIR 6000)
2 LABEL
3 PRODUCT
4 PRESSURE ROLLER
5 ROTATION APPLICATOR
6 CONVEYOR ROUTE
7 PRESSURE ROLLER

Chapter 5 Transport 40045925 BTA Legi-Air 6000 V2
5. Transport
Delivery
If the labeler is normally delivered by freight carrier, please check the packaging for any
damage. If any irregularities are detected, a complaint should immediately be issued to
the freight carrier and also noted on the delivery note.
Scope of delivery
The scope of delivery for the Legi-Air 6000 depends on the range of options and the cus-
tomer-specific application. Please check the system's scope of delivery against the deliv-
ery note when the system is delivered.
Transport and Unpacking

Safety instructions
Danger from lifted loads.
Falling loads can result in serious injuries or death.
- Do not step under the raised load. Make sure that the load does
not become tilted.
- The position of the center of gravity must be observed when
transporting the system. Loads with a displaced center of gravi-
ty have special markings for specific lifting points to be used by
forklifts and industrial trucks.
Danger from tight strapping.
Transport straps are under tension and can whip back in an un-
controlled manner when they are cut, thus causing serious injuries.
̶ Wear safety glasses and protective gloves.

̶ Stand to the side outside the danger zone.
Danger from falling parts.
̶ Wear safety shoes.
Prerequisites
 The labeler is packaged in its delivery state (deviations are possible), meaning
that:
 it is on a pallet
 it is possibly wrapped with stretch film
 it may be secured with additional strapping bands

Tools required
 Suitable industrial transportation vehicles (forklifts, platform floor truck or double
pallet truck...) with sufficient load-bearing capacity (for weight specifications see
chapter "Technical specifications").
 When using a forklift truck, you must drive slowly during the transport.
 2-3 persons, thereby the wearing of safety footwear is mandatory.
 Stable sub-base for the labeler.
 (Safety) steel scissors to remove the strapping.
Fig. 5-1: Legi-Air 6000 Packaging example
Pos. Designations
1 TRANSPORT STRAPPING
2 PALLET
3 STRETCH FILM

Instruction
How to transport the labeler to its utilisation site
Step Approach
1 Transport the labeler to its utilisation site (within a vicinity of 3 m). Accurate
positioning will be carried out during the course of the installation by Bluhm
Weber Group technicians.
The transport straps are under tension and can whip back in an uncontrolled
manner when they are cut, thus causing serious injuries.
2 Remove (if any) wrapping foil and transport strapping.
3 Open the carton and re-

move the filling and packing
material.
Fig. 5-2: Example >> Legi-Air 6000 carton with structure
4 With at least two people, lift the system from the packaging (gripping posi-
tions 1 and 2, see Fig. 5-3). Place the Legi-Air 6000 on its rear on a stable
surface.

Step Approach
Fig. 5-3: Example of gripping positions on the Legi-Air 6000 SES LH and RH
No. Designations
1-2 GRIPPING POSITION > SYSTEM SUSPENSION
4 Before commissioning the system, remove all transport restraints (marked

red tie wraps).
Storage conditions
The environmental conditions required for the storage of the labeler correspond to those
for the normal operation. For details see "Technical Specifications" chapter.
Instruction
How to securely store the labeler
Step Approach
1 Label stock and *² ribbon must be removed from the system
2 Secure the labeler onto pallet(s) and transport the system to its storage
position. For the securing and transporting, observe the safety instructions
stated in the "Transport and Unpacking" section above.
3 To protect against dust, cover the labeler with a cotton or paper towel. No
foils may be used in order to avoid any condensation.
4 The system must be tested before recommissioning the labeler.

Chapter 6 Installation and initial operation 40045925 BTA Legi-Air 6000 V2
6. Installation and initial operation

Safety instructions
Danger through direct or indirect contact with live parts.
DANGER TO LIFE!
Personnel can be killed by coming into contact with voltage-
carrying parts.
breaker to the "0" position, and secure it against accidental re-
̶ Work on the switching cabinet or electrical equipment may only
be performed by skilled electricians and only with tested insu-
lated tools.
chapter "Maintenance/servicing").
Danger from highly flammable label stock.
DANGER OF FIRE!
Foil and label stock are highly flammable. Risk of injury from fire
and smoke.
̶ Keep away from ignition sources and open flames.
Hazards posed by moving parts.
RISK OF INJURY!
Entanglement and risk of being crushed through pneumatically or
mechanically-powered labeler components.
Movements or rotations can start suddenly and abruptly in labeling
mode.
RISK OF BURNS!

Risk from residual energy in pneumatic components.
RISK OF INJURY!
Whipping compressed air hoses, discharged parts or uncontrolled
moving parts can cause injuries.
̶ Before creating the compressed air connection, check all
pneumatic connections for tightness and firmly attach them if
necessary.
̶ The pneumatic system slated for maintenance must be vented
before the dismantling of the pneumatic components is per-
formed.
Risk of tripping through connection cables.
RISK OF INJURY!
Connecting cables for power, compressed air, as well as data and
signal lines are potential tripping hazards and can cause serious
injuries.
̶ Relieve the stress from the connecting cables and route in such
a manner that no danger zones can develop.
There is a risk of injury on edges and corners.
RISK OF INJURY!
Sharp edges and sharp corners can cause abrasions and cuts to
the skin. Always keep the work area clean.
̶ Caution when working in the vicinity of sharp edges and sharp
corners. Remove any items which are not required.
̶ In case of doubt wear protective gloves.
Damage to machine and machine parts

̶ The installation of the labeler may only be performed by tech-
nical personnel.
̶ Only connect or disconnect electrical connections when the
labeler is switched off.
Installation
Only an optimally aligned system installation is able to ensure trouble-free continuous
operation with minimal wear. For optimal system installation, it is essential to carry out
fine-tuning that is adapted to the application conditions. Fine-tuning requires extensive
expertise which is primarily founded on experience gained from working with labeling
technology.
This specific technical knowledge cannot be completely conveyed via the operating in-
structions. The labeler must therefore be installed by a technician of the Bluhm Weber

Group or tested and approved in a final inspection. Damage or consequential damage

which is attributable to improper installation without the necessary fine-tuning, shall not be
covered by the warranty.
Requirements regarding the installation location

 Closed and clean room.
 Flat, solid base, roughness may not exceed 5 mm when using stands from the
Weber Group.
 Sufficient floor load-bearing capacity: 1500 kg/m².
 Low-vibration environment.
 Adequate lighting: 500 Lx.
 No direct irradiation by sunlight or radiators.
 The machine may not be operated in the vicinity of electrostatic or magnetic
fields. This can cause controller faults.
 Proper energy supply (electricity, compressed air) according to the "Technical
Data" chapter.
Positioning of the labeler
 With a retracted applicator (in the home position at the peel bar), the labeler may
not come into contact with the product.
 The panned out or extended applicator must be as parallel to the product surface
as possible. However, depending on the application mode (see page 37) it must
not be allowed to touch the product (distance: 10-50 mm).
 The installation location must allow sufficient access for the operators and ser-
vice technicians. Especially the power switch/plug to disconnect the mains volt-
age must be easily accessible.
 Make sure that all fasteners are sufficiently tightly secured.
 Observe all the points of the "intended use" in the "Safety Regulations" chapter.
Positioning of the labeler

The remote pushbutton box (cf. Fig. 2-3, page 25) may only be mounted outside of the
danger zone, so that an activation of the labeler can only occur in the area secured by
protective devices.
The switch cabinet (unless otherwise agreed upon) must be installed in the vicinity of the
labeler, within the area secured by protective devices (cf. page 23). Observe the available
cable lengths when specifying the distance.
System mounting on a Bluhm Weber Group frame!

If the system is mounted onto a Bluhm Weber Group frame, then please follow the instal-
lation instructions of the supplied frame documentation.

Prerequisites
 The labeler is completely assembled (in the protective enclosure or on the frame
> see the note above).
 The labeler is unpacked and prepared (see chapter "Transport"), in the vicinity of
the labeling site.
 In accordance with the Chapter "Technical data", connections for compressed air
and electricity are installed in the vicinity of the labeling site (max 1.50 metres
away).
 The base area is solid, horizontal and level.
Tools required
 Wrench (for the foot plate adjustment)
 Spirit level
Instruction
This is how to install the labeler.
Step Approach
1 Roll the labeler to the labeling site (where the label is to be dispensed onto
the product). Move the labeler incrementally without the rollers, by pushing
diagonally. Observe all points regarding the "Positioning of the labeler" on
page 46.
2 Horizontally align the labeler with a spirit level.
Connecting the labeler

Incorrect connection or wiring can lead to damages of the compo-
nents used.
The labeler needs electrical power and compressed air to function properly. See the de-
tails in the Chapter "Technical specifications".

Overview of the connections on the labeler

The electrical connections of the labeler are located in the rewinder/unwinder enclosure
on the back of the system, in the area of the label rewinder/unwinder. The following pages
contain the explanation of the individual connections which are shown in Fig. 6-1.
Fig. 6-1: Electrical connections in the rewinder/unwinder enclosure on the rear side
No. Designations
1 IEC 60320 CONNECTION WITH FUSE
2 DISPLAY CONNECTION
3 ETHERNET INTERFACE
4 SENSOR LOW LABEL (PRE-)WARNING
5 PRODUCT SENSOR SECONDARY
6 (OPTIONAL) ENCODER / ANALOGUE PORT PREPARED
7 PRODUCT SENSOR PRIMARY
8 (OPTION) BUS EXTENSION PORT PREPARED
9 ALARM LIGHTS PORT
10 IEC 60320 CONNECTION FOR PRINT MODULE
11 POWER SWITCH (POWER ON/OFF)
12 USB CONNECTION
13 I/O SIGNAL INTERFACE

14 APPLICATOR CONNECTION
15 PRINT MODULE INTERFACE

Connection to the mains voltage
Prerequisites
 Power supply in accordance with the Chapter "Technical data", is installed in the
vicinity of the labeling site (max 1.5 metres away).
 Power switch is OFF (in the "0" position)
 Mains cable and mains connection cable (see in the accessory box)
Instruction
This is how to connect the labeler with the mains connection.
Step Approach
1 Plug the, still not connected, mains voltage cable into the IEC connection of
the system.
2 Connect the print module to the labeler via the mains connection cable (see
page 48, Fig. 6-1, no. 10).
3 Connect the mains voltage cable to the power connector (standard 230 Volt
earthed socket).
Entanglement hazard at the rewinder! After the on-switching, the rewinder will
be activated for a few seconds.
- Maintain a distance from the rewinder!
Power connection for print module: "Printer power supply"

Beneath the rewinder/unwinder enclosure, there is an IEC
60320 connection (female) for supplying the print module with
power (see Fig. 6-2). The connection cable of the print mod-
ule is run out of the side of the stainless steel enclosure and
connected there.
Fig. 6-2: Printer voltage

Connection to compressed air

To localise the compressed air connection, see Fig. 4-3 page 34.
Prerequisites
 Compressed air supply (KS4-CK-6 connection coupling) in accordance with the
Chapter "Technical data", is installed in the vicinity of the labeling site (max 1.5
metres away).
 Compressed air connection line with KS4-CK-6 coupling plugs, pneumatic hose
(see in the accessory box)
 The filter-regulator-pressure gauge combination is mounted vertically (drain valve
on the bottom)
Instruction
This is how to connect the labeler with the compressed air. Instructions refer to Fig. 6-3.
Step Approach
1 Make sure that the gate valve (if present) is in the "OFF" position (slide plate
down, cf. Fig. 6-3 = ON position!).
2 Connect the labeler to the maintenance unit via the connector (4) with the
help of the supplied pneumatic hose. Check the connection for a tight fit (the
hose cannot be pulled off).
3 Connect the coupling plug (3) of the compressed air connection cable with
the coupling of the compressed air supply.
4 If present, pull the slide plate (upwards) to the ON position, to switch on the
compressed air. If adjustments are necessary for the compressed air, refer
to steps 5-7.
5 Pull out the knob (1) of the controller.
6 Set the compressed air to the desired value (5 bar is the default value). For
this, turn the knob counter clockwise (arrow direction "+") to increase the
inlet pressure or clockwise (arrow direction "-") to reduce the inlet pressure.
7 Press the button (1) of the controller down again to interlock it.
No. Designations
1 CONTROL KNOB
2 SLIDE VALVE (IN THE ON POSITION)
3 COUPLING PLUG
4 CONNECTION FITTING (TO THE LABELER)
5 COMPRESSED AIR PRESSURE GAUGE
6 COLLECTING TANK
7 DRAIN VALVE
Fig. 6-3: Filter-regulator-pressure gauge

combination

Connection and positioning of the product sensor

The product sensor inputs are connected parallel to the trigger
inputs of the I/O interface (for example, coming from the conveyor
system), and may not be used together with these.
The connection of sensors which are not included in the scope of

delivery, requires an expert knowledge and may only be per-
formed by qualified personnel.
A trigger signal from a product sensor (optional) is commonly transmitted by a potential-

free contact of the conveying system (CT) to the labeler, in order to trigger a labeling pro-
cess (cf. page 55).
A print process, applicator movement or blow-off operation can also be controlled separate-
ly. This requires several signals and thus also multiple sensors (or signals from the CT).
The M12 industrial connectors for the sensors are located on the back of the rewind-
er/unwinder enclosure. They are labeled with "Product sensor P" (primary) and "Product
sensor S" (secondary). Both sensor inputs can be configured via the HMI display.
The attachment of the product detector and the reflector (if available) must allow
subsequent position changes.
Prerequisites
 No product being transported.
 Sample product
 Power switch is OFF (in the "0" position)
Instruction
How to position the Product detector.
Step Approach
1 Connect the sensor(s) to the labeler (plug in & screw on).
2 Position a product in such a manner that the extending tamp would apply the
label to the desired position on the product.
3 Now position the product sensor at the front or rear edge of the product
(depending on the selected configuration, cf. page 77 and 85).
Only for labeling without product stop:

Time segments for the printing and/or tamp movement must be accordingly
calculated for the sensor position, whereas the sensor must be appropriately
positioned upstream (in the product run direction).
Only for a separately triggered labeling operation:

If the labeling operation is controlled by two trigger signals, then the second
sensor (print trigger) must be positioned upstream at an appropriate dis-
tance. Thereby, the distance must be selected in such a manner, that the
label printing is completed (and if necessary the tamp extended) before the
product reaches the next sensor (application trigger).

Step Approach
4 Only conduct the test run after correct initial commissioning (see page 61).
If the desired position of the label on the product still hasn't been reached,
then perform the respective setting by relocating the product detector (and if
necessary the reflector).
However, it is more comfortable to delay the sensor signals via the display
setting. This is only advisable for non-time-critical applications, because this
increases the cycle time.
"Display" connection
This connection is one of five M12 industry standard sockets located in the rewind-
er/unwinder enclosure on the rear side of the system (cf. Fig. 6-1, page 48). The "Display"
connector socket is exclusively designed for connecting the operator display. An optional
cable set (5 m) will enable different mounting positions for the display.
"Low label sensor" connection

The connection port (see Fig. 6-1, page 48) with the designation "Low label sensor" is a
component of the "low label (pre-) warning" option. If this option is connected it is ready
for used immediately. If this option is not installed, a terminating plug must be plugged into
the "Low label sensor" port instead.
Low Label Warning
The label roll is scanned with a reflective

light sensor (see Fig. 6-4). A signal is
conveyed (see above) as soon as the
label roll diameter is below 98 mm
(+/-3 mm).
In conjunction with the 3-coloured alarm
option, the signal is output via the yellow
lamp. The signal is also provided to the
customer potential-free on the I/O signal
interface for evaluation purposes (see
page 55).
1 = REFLECTIVE LIGHT SENSOR Fig. 6-4: Sensor for low label (pre-)warning (optional)
"USB" and "Ethernet" interfaces

The Legi-Air 6000 is equipped with an Ethernet and a USB interface, type B (cf. Fig. 6-1,
page 48). Through this, it is possible to directly connect the labeler to a PC through a net-
work. The possibly available functions include uploading the firmware (USB only), error
diagnostics, remote operation, backups or the setting of all the parameters.
The "Labeler Remote Control" software supports all these functions. Please contact your
sales agent if you are interested.

"Encoder / Analogue" connection (OPTION)

For electric applicators (except Legi-Air 6000) the optional flanged port enables the con-
nection of a sensor for the distance measurement. The sensor is mounted in front of the
labeler and measures the distance to the product. The result is output as an analogue
voltage, according to which the dispensing stroke (+/- an offset) is then positioned during
the labeling operation.
With Wipe-On systems like the Legi-Air 4050AC the port has a different assignment, and
can be used to connect an optional rotary encoder (DIG).
A DIG is used in applications with a varying product speed to synchronize the feed speed
of the labels with the conveyor system.
"Bus extension" connection (OPTION)

A "Bus Extension" port on the rewinder/unwinder housing (cf. Fig. 6-1, page 48) has also
been prepared. This option offers the possibility of controlling and parameterising addi-
tional peripherals (e.g. product separation, applicators, actuators, etc.) with the labeler.
"Applicator" connection
The 9-pin connector on the back of the rewinder/unwinder enclosure (cf. Fig. 6-1, page
48) is used to connect the applicator (tamp unit). This interface is used for the power sup-
ply, as well as the signal transmission from the co-processor to the controller of the
pneumatic valves and the measuring equipment.

"Alarm lamp" connection
Limited power consumption.

Use only an alarm lamp with LED technology (22701171).
In case of an overloading, the overheating protection will shut off the CPU and aux-
iliary voltage until the temperature has returned to a safe range.
The lamp itself is the only thing required for connection
(cf. Fig. 6-1, page 48) of the optional alarm lamp.
The following contains a listing of the messages with the corre-
sponding meanings.
Fig. 6-5: Alarm lamp
Lamp Meaning
Green lights when the system is ready for operation (READY signal is set)
Yellow lights in case of a label or ribbon end warning
Red lights in case of a system fault / error (READY signal is reset), possible causes:
ribbon or label end, or applicator/sequence fault.
"Printer" connection
The labeler is connected to the digital input/output interface of the print module via this
connection (see Fig. 6-1, page 48). A special adapter cable is used for this depending on
the print module type (see "Technical Specifications").
Print module setup (Printer)

The print module is configured for use in the labeler prior to the delivery. Setup details are
documented in a system check list and are part of the documentation supplied.
Handling information for the print module used can be found in the corresponding user
manual (printer manual) which is also included in the delivery.

"Interface" (I/O signal interface)

The I/O signal interface (within the designation Interface, cf. Fig. 6-1, page 48) is connect-
ed via a 25-pin sub-D connector to the terminal strip (comp. page 58).
The terminal strip provides all the necessary input and output connections for the convey-
or system on screw terminals. Information about the signals can be obtained in the follow-
ing interface description. For details on the terminal connector assignment, please refer to
the supplied wiring diagram.
Inputs (E): Outputs (A):
Bipolar optocoupler (any polarity) Photo-MOS relay, bipolar (any polarity)

Changeover relay (ALARM/READY)
Galvanically isolated
N.O. / N.C. / COM
Input voltage of 20 to 30 VDC N.O. contact, single pole
Selectable signal inversion ("active high" Load capacity: Imax = 200 mA,
or "low active" via display) Switching voltage Umax = 40 VDC
Galvanically isolated from each other
(I) INPUT; (O) OUTPUT
+ 24 V
Label on pad/COM (A)
SYNC/ N.O. (A)
Data Ready/ COM (A)
Home Position / N.O. (A)
Home Position / COM (A)
SYNC/ COM (A)
Trigger 1 "apply" (E)
Print Signal / N.O. (A)
Print Signal / COM (A)
+ 5V (from print module pin 2)
Trigger 3 "AUX" (E)
Auxiliary output (A)
Auxiliary output (A)
READY/ALARM / N.C. (A)
Reprint (E)
READY/ALARM / N.O. (A)
READY/ALARM COM (A)
Label on pad / N.O. (A)
Trigger 2 “print " (E)
Pre-warning / N.O. (A)
Pre-warning / COM (A)
Data Ready/ N.O. (A)
COM input (E)
GND
Fig. 6-6: I/O signal interface (female / view from the outside)

Inputs Function
The system's internal 24 VDC voltage at pin 1, 13 is used solely for supply-
+24 V / GND ing the system options. Load capacity: max. 200 mA (over-current protec-
tion)
Internal auxiliary voltage on pin 2 of the 15 pin sub-D connection of the print
5V module
Trigger 1 Triggering the application process according to configuration. It is possible to

"Apply" assign any trigger input (see pages 77, 81 and 85) on the display.
Trigger 2 Triggering of the print process according to configuration. It is possible to

"Print " assign any trigger input (see pages 77, 81 and 85) on the display.
Trigger 3 Triggering one of the functions configured via display
The last printed label can be printed again with this signal, without the need
Reprint for a new print job (data) (only with print modules from PAX II and SATO SE)
Connection examples:
Customer-side active, provides 24V, common GND
Legi-Air 6000 | Customer side Legi-Air 6000 | Customer side
COM input
Pin 23 Pin 25
Pin 17
Inp. Inp.
2 1
Inp. Inp.
2 1 Pin 17
Pin 25 Pin 23
COM input
Fig. 6-7: Connection examples for the separate or common triggering of printing and application

Outputs Function
general error. Output from the READY/ALARM relay. The signal is active
(READY = N.O.; ALARM = N.C.), if all of the following points are met:
- Ready condition of the printer, regardless of any pending print jobs.
- Printer currently not in pause mode (for PAX).
READY /
ALARM - Labels and ribbon available.
- Operating pressure is within the defined pressure range.
- Labeler ready for labeling (not in standby, no error message)
Auxiliary Configurable signal (e.g. to trigger a barcode scanner...)

output
Home Posi- Signal is active when the tamp is in the home position (the system must be
tion switched on for this).
Print Signal Signal is active during printing (during the feed of a label).
Signal is active, during any ribbon end warning from the printer and optional
Pre-warning during the low label pre-warning (requires pre-warning sensor).
Monitoring of the label presence on the tamp pad (via vacuum measure-
ment).
Label on pad
The signal is active when the label is located in the tamp pad. It is evaluated
by the Legi-Air 6000 and generates an error message in case of an error.
The SYNC output is configurable via display and outputs an impulse after or
SYNC during an application cycle
Signal is output via pin 14 of the 15 pin Sub-D connection of the print mod-
Data Ready ule, and signals the print readiness after the necessary print data has been
completely transmitted.
Connection example:
Legi-Air 6000 Customer-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. 6-8: Connection examples for PLC inputs of the customer

Terminal strip
In the terminal strip, the input and output signals of
the labeler are connected to screwless terminals,
which are required for a secure connection to the
customer's conveyor system.
For details, please refer to the supplied wiring dia-
gram.
Fig. 6-9: Terminal strip
Connections of SES-IO box

The intelligent SES I/O box (cf. Fig. 4-2, page 33)
coordinates the drive, sensors and signal ex-
change to the labeler. Connection sockets must be
connected to the accordingly marked lines to ena-
ble a proper operation.
Variations of the following default assignment

are possible!
For details, please refer to the supplied wiring dia-

gram.
Fig. 6-10: Connections of SES-IO box
Pos. Designations
1 X1 POWER SUPPLY POWER SUPPLY CONNECTION
2 X10 HMI ONLY FOR THE OPTIONAL OLED HMI
3 X19 USB USB CONNECTION (SETUP & COMMUNICATION)
4 X20 ETHERNET ETHERNET CONNECTION (SETUP & COMMUNICATION)
5 X25 RTK VALVE RTK VALVE CONNECTION
6 X30 HOME HOME SENSOR CONNECTION

7 X31 PROX PROXIMITY DETECTOR CONNECTION
8 X32 SPARE SPARE CONNECTION (OPTIONAL ASSIGNMENT)

9 X33 RTK SENSOR RTK SENSOR CONNECTION
10 X34 I/O APPL CONNECTION OF THE APPLICATOR I/O SIGNALS

11 X35 SIGNAL APPL SIGNAL APPLICATOR CONNECTION
12 X36 BRAKE BRAKE
13 X37 RTK ENABLE RTK ACTIVATION CONNECTION

Insert labels and ribbon

Information on how to insert the ribbon can be found in the printer manual supplied
(user manual or quick-reference manual).
Insert the ribbon (thermal transfer foil)

Prerequisites
 Suitable ribbon with inner and outer coating (IC / OC) according to the printer
specifications
 Ribbon width is equal to or greater than the label width
 Tamp is in the service position (cf. page 65)
Instruction
How to insert the ribbon (thermal transfer foil) into the print module.
Step Approach
1 Open the cover of the print module.
2 Proceed according to the manual of the printer. You can usually find an
insert diagram for foils and paper guidance on the inside of the print module
cover.
Inserting the labels

Observe the label roll opening direction!
The Legi-Air 6000 is only intended (without additional options) for use with labels rolled up
on outside, meaning that the labels are stuck to the outer side of the carrier (see Fig. Fig.
6-11, examples 5 - 8). This is the only way the functionality of the roller brake can be
guaranteed.
B = LABEL WIDTH
BT = WIDE BACKING TAPE
H = LABEL HEIGHT
DK = DIAMETER CORE
DR = DIAMETER ROLL
A = DISTANCE (GAP)
Fig. 6-11: Label layout
Prerequisites
 The labels are stuck to the outer side of the carrier (see Fig. Fig. 6-11,
examples 5 - 8).
 Tamp is in the service position (cf. page 65)

Instruction
How to insert the labels into the labeler.
Step Approach
1 Open the cover of the print module, thus interrupting the labeling mode
(Stand-by).
2 Turn the outer unwind disk, so that the set screw is positioned over the
flattened part of the unwind shaft. Now the unwind disk can be removed
easily.
3 Place the label roll (with the external winding) onto the adapter ring (round
aluminum ring with Ø = 76 mm). The label roll must be inserted in such a
manner that the labels can subsequently be inserted into the print module
"facing upwards". Place the unwinder disc back onto the unwinder shaft and
lock it by turning.
4 Remove all the labels on the first 90 cm of the label liner.
5 Insert the web as shown in the following illustrations Fig. 6-12.
Fig. 6-12: Legi-Air 6000 LH and RH
6 Route the paper inside the printing module in accordance with the operating
instructions of your printer (usually you will find a label illustrating the paper
routing scheme on the inside of the print module door).
Please make sure that the Air Assist Tube is not accidentally obscured
by the label liner.
7 Before the carrier can be attached to an empty cardboard sleeve on the
rewinder, the carrier must be guided around the last free deflection roller of
the dancer arm.
8 Turn the rewinder until the carrier paper between the print module and the
rewinder is firmly tensioned (if possible 2-3 windings).
9 Ensure that the label liner from the unwinder is routed in a straight alignment
via the print module all the way to the rewinder.

Initial commissioning
Safety instructions
RISK OF INJURY!
ing mode.
Prerequisites
 Control of product transport
 One or more sample products
 Print media (labels, possibly ribbon) are properly inserted (see page 55)
 Labeler is connected to electricity and compressed air
 Print data can be sent to the print module
 Triggering of the labeling is possible via Product Detector or I/O interface
Instruction
This is how the labeler can be put into operation.
Step Approach
1 Switch on the labeler at the main switch. Also refer to "Labeler on/off switch-
ing" in the chapter "Operation".
RISK OF CRUSHING!
- Maintain a distance from the applicator and remain behind the safety
devices.
2 Close the door of the safety barrier (if available).

4
3 * Press the [start] button of the remote pushbutton box.
Depending on the system configuration (see system check list), the Legi-Air
6000 will start the printing process after the data transfer has completed.
4 Send print data to the printer
5 Switch on the conveyor system to feed products.
4
* Provided the start operations from the printer and servo controllers have been completed and there are no further disturbances.

Chapter 7 Operation 40045925 BTA Legi-Air 6000 V2
7. Operation
Operating the labeler

Safety instruction
RISK OF INJURY!
ing mode.
RISK OF BURNS!
The Legi-Air 6000is an automatic labeling system which does not require any fur-
ther manual intervention after labeling mode has started.
Switching the labeler on/off
Malfunction of the electronics.

̶
When switching on again, wait a min. of 15 seconds between
switching off and on.
The power switch of the labeler and print module must be turned on to enable operation of
the labeler.
Sleep mode: Depending on the configuration (programming 260), the labeler switches to
the “Sleep mode”" (provided the print module is switched off).
In Sleep mode, the display shows " ", while the red LED above the [Stop]
button flashes. In this state, however, the USB and Ethernet interfaces work normally and
allow the exchange of configuration data, updates, etc.
4
Starting labeling mode

After switching on the labeler, the message "Press <START>" will appear in the display,
which means that labeling operation can only be (re)activated after the [Start] button is
pressed. The Legi-Air 6000 is programmed in such a manner (programming 007) that a
safe remote start is possible from beyond the danger zone via remote pushbutton box.

Changing the parameterisation means that it is possible to initialise an * 4automatic start.

This means that, after a preset waiting phase (between 001-254 seconds or directly), the
labeler will activate labeling mode independently. This operation mode requires special
protection measures to guarantee safe operation!
Prerequisites
 The initial commissioning (see chapter "Installation and commissioning") has
been successfully completed.
 Labeler is supplied with compressed air, power, and possibly foil and label stock.
Instruction
This is how to start labeling mode.
Step Approach
1 Switch on the labeler (see page 62).
XX is the version number of the firmware installed in the controller.
After a few seconds, the Legi-Air 6000 will cycle through system information
in the first line of the display.
RISK OF CRUSHING!
- Maintain a distance from the applicator and remain behind the safety
devices.
2 Close the door of the safety barrier (if available).

4
3 * Press the [start] button of the remote pushbutton box.
4
Stopping labeling mode

Prerequisites
 If possible, avoid the interruption during the running labeling cycle
Instruction
This is how to stop labeling mode.
Step Approach
1 Pressing the [SERVICE] button (see Fig. 7-1 on page 64) will stop labeling
mode.
The tamp will immediately move to the home position, and blow off any label
located on the tamp.
2 Switch off the labeler (see page 62).
3 Observe the notices contained in "System decommissioning " (contained in

the following).

System decommissioning
In case of downtimes which last several hours, the label liner

must be removed from the dispenser to avoid errors during
the restart.
The label stock receives a curvature in the bend area of the deflection rollers, which can
lead to errors during the dispensing operation. This property of the labels and the degree
of curvature depend on the material, and can vary greatly between the different types of
print media. Ambient conditions such as high temperatures and high humidity can en-
hance the effect.
By opening the print module door, the labeler will switch to fault mode. Turn off the entire
labeler via the mains switch.
Remove critical label stock from the labeler before longer downtimes and after the
end of work!
Operating and display elements
Pushbutton boxes
Remote pushbutton box
The labeler is equipped with two pushbutton boxes. The remote pushbutton box (Fig. 7-1)
is located outside the danger zone, and thus enables the starting and stopping of the la-
beler in a safe environment (for this, see "Home and service position", page 65).
Pushbutton box [brake release]
This pushbutton box (Fig. 7-2) is located on the front side, next to the applicator. In case
of an emergency stop (see page 26), the application stroke can be moved manually by
pressing a button.
Fig. 7-1: Example of a remote pushbutton unit Fig. 7-2: Example of pushbutton box [brake release]
[Brake release] button

[SERVICE] button
In case of an emergency stop,
Stops labeling mode and moves the
the brake of the hubs can be
tamp into the service position
released.
[START] button
4
Starts the * labeling operation (remote
start)

Home and service position

The home position is equal to the edge height of the application edge (print module). In
labeling mode, the labels are pushed from there onto the tamp. *4Press the [Start] button
of the remote pushbutton box (cf. page 64, Fig. 7-1 ff.), to move the tamp to the Home po-
sition (after a reference movement).
The service position is located above the home position, and enables a free access to the
print module to perform service work (material inserting, cleaning...). For this, press the
[service] button on the remote pushbutton box.
4
Fig. 7-3: Example for reference positions

Operation of the display

The display consists of an LCD display and 5 buttons, as
well as 2 status LEDs. It includes a connection cable with
a 5-pin M12 connector (industrial standard) and is con-
nected on the rear side of the labeler (Fig. 6-1, page 48).
The mounting position is arbitrary and should be, if not
above the print module, at an easily accessible point
close to the labeler. The display is available with different
cable lengths.
Fig. 7-4: Display
Functions of the control buttons
The [Start] button is used to start*5 the labeler. If it is pressed, labeling

mode is started and an error message (if displayed) is acknowledged.
The [stop] button is used to stop the labeling operation. After actuating
the button, the labeler will switch to the stand-by mode. Only now will it be
possible to access a controller menu. A further actuation of [Stop] will
switch the labeler into sleep mode and, as after switch-on, an error
message (if displayed) will be acknowledged.
Risk of crushing through movement of the tamp! *5

If to "automatic start" (value 001 to
254), then after the (Stop) button is pressed for the second
time, the tamp automatically moves back to its home posi-
tion after the parameterized time has elapsed.
- Maintain a distance from the tamp
Risk of crushing through movement of the tamp! *5

Even without a printed label, an application cycle can be
triggered with the JOG function.
- Maintain a distance from the tamp
The [Enter] button has 3 functions:
a) JOG function*5: During labeling mode, the Legi-Air 6000 can be
triggered with this button.
b) In combination with other buttons, to call up menus.
c) In the menus, [Enter] is used to edit a parameter or to confirm entries.
The [] / [] buttons each have 3 functions:

a) In combination with other buttons, to call up menus.
b) To navigate in menus
c) To change parameter values, ([] reduces / [] = increases).
The auto repeat function of buttons allows a fast change of high values, if
you keep the respective button pressed.
*5 Only applies to labelers with protection device when the door contact switch is closed.

Status LEDs
The [start] and [stop] buttons each have one status LED positioned above them. The illu-
minated green LED above the [start] button signals the "labeling readiness". The red LED
(above [Stop]) indicates an interruption of the labeling mode.
Program menus
PROGRAMMING MODE may only be operated by trained per-
sons!
̶ Incorrect programming may cause malfunctions!
The display of the Legi-Air 6000 includes three menu

modes which can be opened and closed using key
shortcuts. In the standby mode, press each of the follow-
ing buttons simultaneously to open the desired menu:
Fig. 7-5: Buttons below the display
[] + [Enter] = FUNCTION MENU

[Enter] + [] = CONFIGURATION MODE *
[] + [] = PROGRAMMING MODE *
* Password protected
Firmware version current configuration Label

of the controller data set counter
Status bar
Fig. 7-6: Display explanation
ERROR ACKNOWLEDGMENT, see Functions of the control buttons [Start]/[Stop] page 66.
Display of the firmware version

The current firmware version (firmware = operating system) of the controller is displayed
here (firmware history on page 94).
Current configuration data set

The Legi-Air 6000 offers the option of storing up to 4 different parameter sets. Each data
set can be used for the individual parameterisation of the labeler (e.g. for different produc-
tion conditions).

Label counter
The 5-digit number shows the number of completed application cycles of an operational
phase. The counter is automatically set to "00000" when the labeler is switched on. If a
negative 4-digit number is shown, the counter will be operating in "Countdown" mode.
Status bar
The status bar provides information about the current state of the labeler and its activities.
A 3-digit "info number" on the right of the status bar is displayed to provide additional in-
formation and is explained in the "Troubleshooting" chapter.
Stand-by mode
The "Stand-by" message is displayed after labeling mode is interrupted, e.g. by opening
the protective enclosure or pressing the [Stop] button. The vacuum to hold the label is
switched off. A menu for the applicator controller can only be selected from stand-by
mode.
FUNCTION MENU
The function menu can be reached by simultaneously pressing the [] and [Enter] but-
tons, assuming the labeler is in stand-by (see above). This menu includes some basic
settings of the labeler with the following sub-menus:
...
Menu diagram
see next page

...

LABEL COUNTER
Here, you are provided with the opportunity to specify a certain value between 0-9999 for
the label counter. With the input of a value greater than "00000", you also activate the
countdown function. This means, that the entered value will be counted down during the
labeling operation at each application cycle. The display will then show a "minus" before
the counter value. The counter value is equivalent to the remaining application cycles.
Upon reaching the end value "-0000", the labeler will automatically stop.
 Press the buttons [] or [] to go to the next parameter.

 Press [Enter] to edit the front digits, or press [Enter] again to switch to the rear
digits.
 Afterwards, press the [] or [] *buttons to increase / decrease the value
of the parameter to be edited (the respective cursor will blink).
 To exit the parameter settings please press [Start] or [Stop] respectively.
RESET LABEL COUNTER

This function resets the counter value of the label counter.
 Press the [] or [] *buttons to switch to the next parameter.

 Press [Enter] to reset the counter to "00000".
*Fast forward function when the [] or [] button is held down.

DISPLAY SETTING
This sub-menu contains the display settings. Here you can change the contrast and
brightness and select the menu language. The following languages are available, de-
pending on the language pack:
Language Pack 1 (22800870): English, German, Italian, French, Dutch, Norwegian, Swe-
dish, Turkish
Language Pack 2 (22800871): English, Greek, Russian, Czech, Latvian, Polish, Spanish,
Portuguese
Press the [] or [] *buttons to switch to the next parameter.

Press [Enter] to open the time settings.
To exit the parameter settings please press [Start] or [Stop] respectively.
The DISPLAY SETTING parameters:

- LCD BACKLIGHT >> brightness of the background lighting
Setting value between 001-040.
- LCD CONTRAST >> Contrast setting between 001-100
[]
[]
 Press the [] or [] *buttons to switch to the next display setting.
 Press [Enter] to enable the parameter alteration.
 During the language selection, the setting is changed directly with [Enter].
 For the parameter values, press the [] or [] *buttons to increase / decrease
the value to be edited (the respective cursor will blink).
 To store the value, please press [Enter].

EVENT COUNTER
A number of different "event counters" can be queried using this function. These provide
useful statistical information about events which are counted automatically while the
labeler is running.
Event Counter information

E00 Number of all stopped application cycles without failure.
Number of faults that have occurred under the corresponding error code (see
E01 to E22 page 107 ff).
7
EV1 * Total number of printed labels.
7
EV2 * Number of all tamp extension movements.
7
EV3 * Number of blow-off processes.
7
EV4 * Total number of communication errors (incl. autom. recovered errors).
7
EV5 * Maintenance counter is incremented by 1 after completion of 256 labeling cycles
*7 All counter values are stored in the non-volatile memory of the labeler. The counter val-
ues are stored at the time of a fault or in stand-by mode. This means, if the system is
switched off in the "READY" mode, the counter values EV1 EV5 can differ greatly from the
actually counted values.

 Press [Enter] to go to the event counters.
5 digit counter,
Maximum value = 65535
(afterwards start at 00000)
[] 8 digit counter,

Maximum value: 99999999
[]
(afterwards start at 00000000)
 Press the [] or [] buttons to go to the next event counter.


CYCLE SEQUENCE
This sub-menu allows you to select a sequence of labeling cycles to apply 2 labels con-
secutively to a single product. This requires a special applicator and activation of the re-
spective function (programming 046). A classic usage case for pallet labeling.
(Then, the following default configuration will apply : Cycle 2 = front side labeling / / cycle
3 = side labeling. If your system has the option "external selection of the cycle sequence"
via interface signals, then the external selection will always have priority over a manual.)

 Press [Enter] to open the cycle settings.
CYCLES SEQUENCE parameters
 Press the [] or [] *buttons to switch to the next cycle type.

LAN
If the Legi-Air 6000 is equipped with the optional LAN adapter (s. Ethernet port, page 48),
you can access the setting parameters through this function.
After opening the submenus, the current IP address and MAC address of the LAN adapter
are displayed. At the beginning of the IP display, a "d" or "s" will be shown. A “d" means
that the interface is configured with a dynamic IP address (assigned by a DHCP server),
whereas a static IP address is assigned with "s".
 To store all the LAN parameters, press the [] or [] buttons to reach the display of
the IP and MAC address, and press [Enter].
 To exit *11 the function menu, please press [Start] or [Stop] respectively.
*11 When you leave this menu without having first saved all LAN parameters, the changes will be discarded.
LAN parameters
In order for the changed LAN parameters to be adopted in this menu, press the [Enter]
key before leaving the menu. During the storage, a countdown will be displayed.
With the first LAN parameter "DHCP" you can set the IP address to static "0" or "1" to dy-
namically (will be assigned by a DHCP server). With a dynamic IP address setting, the fol-
lowing parameters are not important.
Afterwards, the settings of IP address and the gateway are performed.

 Press [Enter] to enable the parameter editing.
 Afterwards, press the [] or [] *buttons to increase / decrease the value of the
parameter.

CONFIGURATION menu
The configuration menu can be reached by simultaneously pressing the [Enter] and []
buttons, assuming the applicator is in stand-by.
This menu includes parameter settings for the entire applicator configuration, which speci-
fies the process of a print application cycle. The Legi-Air 6000 is able to store up to 4 dif-
ferent applicator configurations (parameter sets). The first menu item in the configuration
menu allows a selection of configuration 0 to 3.
On page 91 you have the option of entering all parameters in a list.
CONFIGURATION SELECTION
 Press the [] or [] buttons to select the desired configuration from the four configu-
rations 0 - 3.
 To exit the configuration selection, please press [Start] (for the labeling mode) or
[Stop] (for standby).
 Press [Enter] to go to the parameters of the selected configuration.
CONFIGURATION parameters
The display shows a three-digit number in the first line after "CONFIGURATION" (e.g.
"101"). The first number (left), stands for the current configuration (0-3). The following dig-
its (01-20) represent consecutive numbering of the 20 configuration parameters.
Depending on the applicator type, different parameters are available:
Pneumatic applicator (01-16) and electrical applicator (01-06, 08-11, 13-20).
Line 2 contains one of the following configuration parameters respectively:
8
*
8
*
8
*
8
*
x = Configuration 0…3 *8Only applies for electrically actuated applicators (not for Legi-Air 6000)

ENTER PASSWORD:
If a configuration parameter is called up for editing with [Enter], you will be prompted to
enter a PASSWORD, in order to restrict access to authorized people. The code is "123",
and access is initially valid for all parameters, but only until the [stop] button is pressed
twice, or the labeler is switched off and then on again.
 Press the [] or [] *buttons to increase / decrease the number value.
 Press [Enter] to confirm the password entry.
 If a valid password is entered, you return to the configuration parameters.
 If an invalid password is entered " " will be displayed

PRINT TRIGGER:
This is used to define the start of printing (a label). The labeler receives the signal either
directly from the photo cell input via the corresponding M12 connector, or via the signal in-
terface. Both inputs (M12 plug and I/O signal interface) have a "logical OR connection"
e.g. both signals have equal rights, but only one of the two connection types may be used
for triggering.
There are various input configurations to choose from (edge triggering, level triggering...).
The cycle monitoring function ensures the highest degree of labeling safety. Here, the sta-
tus of the trigger signal is verified to ensure that it's inactive when a trigger is expected for
the continuation of the labeling cycle (in this case, to print). If the signal continues to be (or
is again) active, the labeler will switch to the fault mode, and will thus enable the detection
of any synchronization problems in critical applications. The following table shows the
function of the corresponding parameter value:
Para-
meter Function
Value
00 automatic printing (if print data is available)
01 Primary sensor input / (I/O: Pin 17) Edge triggering (rising edge):
02 Secondary sensor input/(I/O:Pin 23) Triggering in case of a leading edge,
meaning the change from "low" to "high". A
03 Aux. input on the I/O interface: Pin 19
trigger is only accepted when "Expect
04 Internal connector on the applicator-PCB trig. .." is displayed. Outside of this phase,
J5.5 all triggers will be ignored.
05 Primary sensor input / (I/O: Pin 17)
Level triggering (high level):
06 Secondary sensor input/(I/O:Pin 23)
Triggering in case of "high" signal. Applica-
07 Aux. input on the I/O interface: Pin 19 tion cycle repeat as long as the signal is
Internal connector on the applicator-PCB active (high).
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) Function is the same as with edge triggering
(leading edge) plus synchronization security.
Purpose of monitoring: The trigger signal
12 Internal connector on the applicator-PCB must be in the LOW level again prior to the
J5.5 labeling cycle start, otherwise the Legi-Air
6000 will switch to the fault mode.
13 Primary sensor input / (I/O: Pin 17) Level triggering with cycle monitoring (high
14 Secondary sensor input/(I/O:Pin 23) level):
Aux. input on the I/O interface: Pin 19 Function is the same as with edge triggering
15
(leading edge) plus synchronization security.
16 Internal connector on the applicator-PCB
J5.5
must be in the LOW level again prior to the
labeling cycle start, otherwise the Legi-Air
6000 will switch to the fault mode.
17 Primary sensor input / (I/O: Pin 17) Edge triggering (falling edge):
18 Secondary sensor input/(I/O:Pin 23) Triggering in case of a falling edge, mean-
ing the change from "high" to "low". A
trigger is only accepted when "Expect trig.
20 Internal connector on the applicator-PCB ..." is displayed. Outside of this phase, all
J5.5 triggers will be ignored.

Para-
meter Function
Value
21 Primary sensor input / (I/O: Pin 17)
Level triggering (low level):
22 Secondary sensor input/(I/O:Pin 23)
Triggering in case of "low" signal. Applica-
23 Aux. input on the I/O interface: Pin 19 tion cycle repeat as long as the signal is
Internal connector on the applicator-PCB active (low).
24
J5.5
25 Primary sensor input / (I/O: Pin 17) Edge triggering with cycle monitoring (falling
edge):
(falling edge) plus synchronization security.
27 Aux. input on the I/O interface: Pin 19 Purpose of monitoring: The trigger signal
28 Internal connector on the applicator-PCB must be in the HIGH level again prior to the
6000 will switch to fault mode.
29 Primary sensor input / (I/O: Pin 17) Level triggering with cycle monitoring (low
level):
(falling edge) plus synchronization security.
32 Internal connector on the applicator-PCB must be in the HIGH level again prior to the
6000 will switch to fault mode.
 Press [Enter] to edit the configuration parameter (for password prompt, see page 76).
 Afterwards, press the *buttons [] or [] to increase / decrease the value of the
parameter (valid range: 000-032).
 Press the [] or [] buttons to go to the next configuration parameter.
 To exit configuration selection, please press [Start] or [Stop] respectively.

LABEL TIMEOUT:
The print process for the label must be started within the preset time, otherwise the labeler
will switch to fault mode. The query is performed via the print signal of the print module.
The timeout starts with the request for the label, i.e. with (external or autom.) triggering for
printing. A special parameter in the "cycle options" (see page 90) allows the E09 error to
be skipped if it is displayed as a result of a print request (Print Trigger) without the availa-
ble print data.
The print signal is not examined with the value "000". This service function saves con-
sumable material during adjustment work on the applicator. Because the labeling cycle
will start without a label (assuming the vacuum test is disabled).
 Press [Enter] to edit the configuration parameters (for password prompt, see page 76).
parameter. (Unit = value x 10ms, with value = "255" the wait time will be infinity,
the value "000" starts the cycle without a label).
VACUUM LEVEL:
This parameter determines the sensitivity of the vacuum measurement. The highly sensi-
tive measuring sensor registers even very slight pressure losses, which provides a practi-
cal setting range from 0-10 points. A value of "005" will already ensure a sufficient vacuum
check. Values beyond that are already in the sensitive to highly sensitive measuring
range.
 Afterwards, press the buttons [] or [] to increase / decrease the value of the
parameter. (Unit = value x 1/33 bar, for value = "0" the function is switched off).
*Fast forward function when the t[] or [] button is held down.

VACUUM TIMEOUT:
This timeout enables you to specify for how long the labeler should try to determine the
presence of a label at the tamp before it generates an error message. Meaning that within
the set time the vacuum must have fully developed, otherwise an error will occur. Usually
the vacuum is checked after the printing process. For special applications, the value can
set to "000" which will start the vacuum check with the start of printing.
parameter. (Unit = value x 10 ms, value = "0" value immediate vacuum test, with
value = "255" the labeler will wait infinitely for the vacuum to be built up (200 = 2
seconds = default).

EXTENS. TRIGGER: (EXTENSION TRIGGER)

This is used to program the trigger signal is to extend the applicator. After the label has
been printed and recognised on the tamp, the point in time within the labeling cycle where
the trigger is expected. The interpretation of the parameter value is comparable to that of
the PRINT TRIGGER. For this, please refer to the table on page 77.
Para-
meter Function
Value
00 immediate extension of the applicator
02 Secondary sensor input/(I/O:Pin 23) Triggering in case of a rising edge, meaning
the change from "low" to "high". A trigger is
only accepted when "Expect trig. .." is
04 Internal jumper on the applicator PCB displayed. Outside of this phase, all triggers
will be ignored.
05 Primary sensor input / (I/O: Pin 17) Level triggering (rising edge):
. Triggering in case of "high" signal. Applica-
. tion cycle repeat as long as the signal is
Further, cf. page 77. active (high).
.
32

EXTENS. DELAY: (EXTENSION DELAY)

This parameter enables the programming of the “EXTENSION DELAY” parameter, be-
tween the trigger signal and the actual movement of the stamp. The delay starts with the
(external or autom.) triggering. EXTENS. DELAY is ignored if the parameter APPLICA-
TOR TRIGGER has the value "000" (cf. page 81).
parameter (unit = value x 10ms, value "000" = no delay).

EXTENS. TIME: (EXTENSION TIME)

This parameter is only available with pneumatically-driven applicators and Legi-Air
6000!
The "EXTENSION TIME" defines the time which elapses from the start of the stroke until
the beginning of the blow-off operation. The value "000" switches to the labeler into the
Blow-On mode, where the label is blown off directly without an applicator movement oc-
curring.
The specified time should correspond to the actual duration for the extension of the entire
stroke. The duration will be equal to the value x 10ms (factor can be switched to 100 ms
"Programming 0013").
If the specified time value is exceeded due to a different parameter configuration, the label
will be immediately blown off on to the product unless the labeler is waiting for a trigger
signal (e.g. "BLOW TRIGGER", see page 85, or by the "variable stroke” sensor). When
using the option "variable application stroke", the EXTENSION TIME is normally set to a
low value (e.g. "002"), in order to continue with the variable range of the stroke after a
constant extension length.
(Only for Legi-Air 4050WX: If the Bit2 (+004) of "Programming 0013" is set, the valve for the pivoting-out will switch off after
the EXTEND TIME. The applicator is then without power and is held by spring force).
parameter (unit = value x 10 or 100 ms, value "000" = Blow-On Mode).

PROXIMITY T.OUT: (PROXIMITY TIMEOUT)

The parameter "PROXIMITY TIMEOUT" is required when an optional proximity sensor is
used on the tamp plate. This will switches as soon as an object reaches its adjustable
scanning range. The applicator dispenses the label and returns to the home position. De-
pending on the application type, the parameterization will be different!
A parameter value of more than “000” enables the "variable application stroke", which re-
quires an optional sensor on the tamp plate. The entered value (unit = value x 10 ms) de-
fines the maximum wait time for the applicator during the extension time, during which the
variable stroke sensor must have acquired the product. Otherwise, the E14 error message
will be output. The wait time is displayed and counted down.
A special function of the "cycle option" (see page 89) allows this error message to be
skipped. The Legi-Air blows off the label, and continues with the cycle normally.
A parameter value of "255" will specify an infinite wait time for the triggering of the prox-
imity sensor (a time display will not occur in this case).
parameter. (Value must be "000" if no "Variable stroke" option is installed).

BLOW TRIGGER:
This is used to adjust the trigger signal to blow off the label. With the value "000", the label
is blown off without delay or automatically. Greater values will cause the labeling cycle to
pause at this point, and the applicator will wait for the predefined trigger signal.
In addition, the trigger can be used to control the external stop function or to start the la-
beling operation, depending on the configuration (the "programming").
The interpretation of the parameter value is comparable to that of the PRINT TRIGGER.
For this, please refer to the table on page.
If the labeler is operating with a variable application stroke, the value must be "000" ac-
cording to the factory setting.
Para-
meter Function
Value
00 Automatic blow-off of the label or "Variable stroke" operation mode
02 Secondary sensor input/(I/O:Pin 23) Triggering in case of a rising edge, meaning
the change from "low" to "high". A trigger is
only accepted when "Expect trig. .." is
04 Internal jumper on the applicator PCB displayed. Outside of this phase, all triggers
will be ignored.
05 Primary sensor input / (I/O: Pin 17) Level triggering (high level):
. Triggering in case of "high" signal. Applica-
. tion cycle repeat as long as the signal is
Further, cf. page 77 active (high).
.
.
32

BLOW DELAY:
This configuration parameter delays the blow-off process by the value pre-set here. How-
ever, the delay will remain active if the previous parameter "BLOW TRIGGER" was set to
“000”. However, the delay time begins at the end of the extension movement.
parameter (unit = value x 10ms, value "000" = no delay).
BLOW TIME:
This determines the blow-off time and thus the duration of the blow-off valve activation for
transfer of the label onto the product. The allowable setting range is between 000 and 255
(value x 10ms).
A lower value leads to higher cycle speeds, which is particularly beneficial for time-critical
applications. This will, however, increase the interference sensitivity for external factors
(temperature, oil content of compressed air...). Higher values additionally prolong the cy-
cle time due to the fact that a higher air emission will require a longer filling time of the air
storage (in the Legi-Air 6000).
parameter (unit = value x 10ms, value "000" = Tamp-On-Mode).

HOME TIMEOUT:
This setting determines the maximum amount of time that the applicator will wait for a signal
from the home position sensor during the retraction movement, before an error message is
displayed. This also applies after the labeler is switched on, if the tamp is not in the home
position because, for example, the compressed air still has not been switched on.
parameter (unit = value x 100ms, value "000" = no query of the home position,
value "255" = infinite wait time for the home position signal).
SYNC PULSE DELAY:

The SYNC signal is made available at the I/O interface (see page 55). It usually starts at
the end of an application cycle, with arrival of the tamp pad in the home position. With this
parameter is possible to delay the impulse start, for example, to control a downstream
pusher unit to press on the label. The duration of the delay is equal to the input value x 10
ms (i.e. max. "255" = 2.55 s).
In combination with the SYNC PULSE TIME = 000 (see below), the SYNC signal activa-
tion is delayed by the time set here, and will end when the tamp pad arrives in its home
position (e.g. for use as a BUSY signal = "Cycle active"). For more information, refer to the
following section under "SYNC PULSE TIME".
parameter (unit = unit = value x 10ms).

SYNC PULSE TIME:

This parameter is used for setting the pulse length of the SYNC signal which is made
available at the I/O interface (see page 55).
Normally the SYNC pulse starts at the end of an application cycle, when the tamp pad ar-
rives in its home position. The length of the pulse corresponds to the value x 10 ms.
If the value is set to "000", the SYNC signal will be event-driven. If the SYNC PULSE DE-
LAY is also zero, it will be activated with the first relevant trigger of a cycle and deactivat-
ed once the tamp is back in the home position (in this case, the SYNC output can be used
as a trigger-acknowledge signal).
For a SYNC PULSE DELAY greater than zero, signal activation will be delayed by the ap-
propriate time value.
The following depiction illustrates the relationship between SYNC PULSE ...TIME and
...DELAY:
Fig. 7-7: SYNC diagram
Pos. Designations
(A) ACTIVE
P PASSIVE
CT CYCLE TIME
SPD SYNC PULSE DELAY
SPT SYNC PULSE TIME
parameter (unit = value x 10 ms, value: "000" = see above).

BARCODE RD TIME:
If the labeler is equipped with an optional barcode scanner on the tamp pad, this parame-
ter can be used to set the read time. The duration is equal to the input value x 10 ms (i.e.
max. "255" = 2.55 s).
With the "SYNC PULSE DELAY" parameter (see page 87), it is possible to delay the
transmission of the scan result accordingly after the read time has elapsed.
When using a gap scanner (scans the bar code in the gap between the print module and
tamp, during the printing process) the time must be "000".
parameter (unit = unit = value x 10 ms).

CYCLE OPTION:
Here, predefined program processes are available for selection. The processes can be
combined with each other using the arithmetic total or can be activated separately:
+ 1 deactivates the "Variable stroke" function and activates the vacuum or "Label on
pad" poll during the tamp extension movement.
+2 activates the tamp retraction at the end of the blow-off sequence (usually the
tamp retracts simultaneously with activation of the blow-off valve).
+4 disables the "variable stroke" function and ignores vacuum loss during the tamp
movement.
+8 activates the corner wrap application for systems with a 90°-180° rotating tamp
(option).
+ 16 activates the vacuum or "label on pad" query after the label handover (during the
tamp retraction) in the Tamp-On mode (if Blow Time = "000", see page 86).
+ 32 activates the function to control the RFID reject unit. If this function is used, sta-
tus monitoring for the print module must be turned off (programming 004, value
"+016") because otherwise the labeler will switch into the fault mode if there is a
Bad Tag.
+ 64 deactivates the error "timeout label". In this case, the labeler will ignore the print
request when the time-out expires and will restart the timeout during the next
"Trigger Printing".
+128 deactivates the timeout error for variable stroke (not to be confused with unlim-
ited waiting >> PROXIMITY T.OUT VAR HUB = "255").
parameter (value: "000" = no program sequence selected, "001" = 1st function;
"002" = 2nd function; "003" = 1st and 2nd function...).

EXT. SPEED (cm/s): 100

Does not apply to Legi-Air 6000.
RET. SPEED (cm/s): 100

EXT. STROKE (cm): 023.0

PLATE ALIGN.(mm): 025


Parameter list for configuration CFG 0-3

Here it is possible to enter all parameters of the configuration menu. A total of 4 parameter
sets are available.
Product / batch / line >
Value for Value for Value for Value for

Configuration parameters
Pneumatic applicator (01-16), electrical applicators (01-06, 08-11, 13-20).

PROGRAMMING
Incorrect parametrisation can lead to process and function errors
that can also cause mechanical damage.
This also applies for changes to reserved or undocumented
parameters, as well as parameterizations which are beyond the
valid parameter range.
̶ The parameterization may only be conducted by trained per-
sons!
PROGRAMMING mode allows you to view all 256 service parameters and provides ac-
cess to a further sub-menu. A five digit password authentication is in place, to protect the
parameters.
DIAGNOSTICS
The diagnostic function can be accessed both in the standby as well as error state if the
[], [Enter], and [] buttons are pressed simultaneously. The same will occur you switch
on the labeler while pressing any button. The display will switch to a numeric display
which looks like this:
To exit the diagnostic function, simultaneously press the [start] + [stop] buttons on the dis-
play, which then triggers re-initialization at the same time.
An interpretation of the numerical data requires a high level of expertise, in order to be
able to diagnose common problems of the labeler.
All numbers are in the hexadecimal notation and have the following meanings:
top line
a) Digits 1-2 represent the code of the last message that was displayed in the second line.
b) Digits 3-4 represent*9 the status of the rewinder-board (slave).
c) Digits 5-6 represent the status of the inputs from the motherboard.
d) Digits 7-8 represent*9 the status of the inputs from the applicator board (slave).
e) Digits 9-10 represent*9 the status of the inputs from the 2nd applicator board (slave).
f) Digits 11-12 represent*9 the status of the outputs of the motherboard.
g) Digits 13-14 represent*9 the status of the outputs of the applicator board (slave).
h) Digits 15-16 represent*9 the status of the outputs of the 2nd applicator board (slave).
i) Figures 17-18 represent * 9 the analogue value of the vacuum sensor on the applica-
tor board (slave).
j) Digits 19-20 represent*9 the analogue value of the vacuum sensor on the 2nd applica-
tor board (slave).
*9 if hardware is available and functioning properly

bottom line
k) Figures 1-6 represent the communication error counter of the motherboard (transmit-
ting, receiving and checksum errors).
l) up to p) reserved!
q) Digits 19 to 20 represent the status of the display board incl. the codes of the buttons
pressed on the display.
Firmware history
The firmware is the "operating system" of the labeler controller. The following is a chrono-
logical list of all firmware versions which were deployed up to the time these operating in-
structions were published.
AP4050.20u
Creation 01.10.2017 Series Firmware
V4050.20 - 4050.20g
Development and prototype versions

Chapter 8 Maintenance/Repair 40045925 BTA Legi-Air 6000 V2
8. Maintenance/Repair
Safety instructions
Danger posed by direct or indirect contact with live parts
DANGER TO LIFE!
If people come into contact with parts that have become live
through faults.
̶ Work on the electrical control cabinet and on electrical
equipment may only be performed by skilled electricians.
"Maintenance" chapter).
breaker to the "0" position and secure it against accidental re-
RISK OF INJURY!
ing mode.
̶ Disconnect the labeler from the power and compressed air
before carrying out work on the device.
Risk from residual energy in pneumatic components

Whipping compressed air hoses, discharged parts or uncon-
trolled moving parts can cause injuries.
̶ Disconnect the labeler from the compressed air supply before
carrying out work on the device
Health hazard due to improper handling of lubricants and

cleaning agents
HEALTH HAZARD!
Improper handling can lead to health hazards.
̶ For the utilized lubricants and cleaning agents, it is necessary
to observe and comply with the respective product infor-
mation of the applicable safety data sheets from the manufac-
turer, as well as the safety and disposal regulations.

RISK OF BURNS!
Damage to machine and machine parts

Missed or incorrectly performed maintenance/servicing and
repair work will reduce the operational availability of the ma-
chine. This can result in consequential damages and the exclu-
sion of warranty claims.
Machine functions are to be monitored continuously.
Exceptional noise developments or unusual movements (such
as jerking, hitting, etc.) are indications of malfunctions and must
be checked.
̶ All recognized defects must be resolved promptly and profes-
sionally.
̶ It is prohibited to operate the machine until a proper functional
state has been restored - especially if the protection devices
are defective.
̶ The maintenance/repair of stand-alone machine or system
components (e.g. print module, air conditioner...) must be
complied with and performed in a professional manner at the
prescribed intervals. (Refer to the supplied documentation).
̶ The maintenance/repair of the labeler may only be performed
by the technical personnel. Only cleaning work may be per-
formed by the operator (
̶ Approved persons see page 22).
Recommended cleaning agents and lubricants

Use our cleaning set for cleaning work (*21800981).
The cleaning instructions (22800512) are included with the cleaning kit. This provides de-
tailed information about the required cleaning work, as well as further information about
the safe use of cleaning agents.
For the lubrication of casters and guide shafts of the linear stroke, the manufacturer rec-
ommends the following product:
 Paraffin oil DIN 51502: CLP 220

 Temperature range: -30°C to +70°C
 Oil press for casters (*40022726)
 Oil, Molyduval Soraja GAM 220, 1 litre (*40022727)
* Product recommendation! Can be obtained from the Bluhm Weber Group using the 8-digit article number.

Daily repair/maintenance (after approx. 8 operating hours)

Prerequisites
 Labeler is separated from the voltage and compressed air
 Repair/maintenance work has been carried out on stand-alone machine or sys-
tem components (e.g. scanner, camera, air conditioner...).
Tools required
 Alcohol (*21800915) and/or roller solvent (*21800977)
 Lint-free cloth (*21800978)
 Label remover (*21800771)
Instruction
How to perform the daily repair/maintenance.
Step Approach
1 On a daily basis or after changing the label roll, clean the drive roller with a
roller solvent. For this, spray some roller solvent onto a lint-free cloth and
wipe down the rubber roller. Wait until the drive roller is completely dry,
before you reinstall the label liner.
2 Check label guides and deflection rollers, as well as the peel bar for any
adhesive deposits / labels (residue). Remove them with label remover or
alcohol.
3 Check the water separator of the compressed air connection. Drain it by

opening the release valve on the bottom.
Water accumulation in the water separator is an indication that the operating
pressure air supply is not working properly. Water/oil - mixture in the water
separator are a cause for alarm! The reason for this must be clarified. If oil
enters the compressed air circuit, this will generally lead to failures! The
installation of an additional building-side pre-filter could be required (for 300
l/min flow rate at 7 bar, 10 µm).
4 Check the tamp surface as well as the peel bar for any adhesive deposits.
Remove them with label remover or alcohol.
5 Inspect/clean the air filter of the protective enclosure (if available).

Weekly servicing/maintenance (after approx. 40 operating hours)

Prerequisites
Tools required
 Alcohol (*21800915) and/or roller solvent (*21800977)
 Lint-free cloth (*21800978)
 Label remover (*21800771)
 Compressed air spray (*21800768)
 Soft brush (round or flat approx. 10 mm)
Instruction
How to perform the weekly repair/maintenance.
Step Approach
1 Clean the tamp surface, the application edge and all paper guiding parts to
remove any adhesive deposits. To do this, use label remover or alcohol.
Do not use the operational compressed air supply for the following cleaning
work, since this is sometimes insufficiently dry (oil/water residues). If the
electronics come into contact with moisture, this will lead to damages!
2 Clean the (cooled down!) surface of the servo motor to avoid possible heat
congestions.
3 Clean all the sensors (product, crash-sensors, label end warning sensor,
label gaps sensor) carefully with a soft brush and compressed air spray.
4 Remove any dust deposits from the system enclosure.
5 Check all hose connections for tight fit and possible leaks.
6 Check the components (carbon tube, 3D print tamp) of the applicator for
visible cracks or breaks.
7 Check whether all the rollers will still move freely and that the axles of the
rollers are still firmly attached.
8 Check the mechanics of linear or swivel unit incl. the tamp for a tight fit of all
screws and connections.
9 Check the emergency devices for their functionality.

Monthly servicing/maintenance (after approx. 200 operating hours)

The lubrication of the linear axis (not for rotation applicator) is performed with an oil soaked
felt insert. This must be regularly oiled through the (upper) grease nipple (see Fig. 8-1).
The monthly greasing interval decrease under adverse ambient conditions (e.g. high hu-
midity, dust and or high temperatures).
Prerequisites
 Labeler is separated from the volt-
age and compressed air
Tools required
 One-hand oil press
 Oil (see recommendation on
page 96)
Fig. 8-1: Grease nipple
No. Designations
1 GREASE NIPPLE
2 ONE-HAND OIL PRESS
Instruction
How to perform the monthly servicing/maintenance.
Step Approach
Lubricate the carriage of the linear axis with 1-2 strokes of oil from the hand-
1 press.
Check the guide clearance of the carriage. A correction is possible through
2 adjustment of the rollers (eccentric cam).
RISK OF CRUSHING! Maintain a distance from the applicator. Step behind
the safety equipment.
3 Afterwards, check the linear unit for proper functionality.

Half-yearly servicing/maintenance (after approx. 1000 operating hours)

Prerequisites
Tools required
 Vacuum cleaner
Instruction
How to perform the half-yearly servicing/maintenance.
Step Approach
1 Replace all air filter cartridges (if present).
Do not use the operational compressed air supply for the following cleaning,
since this is sometimes insufficiently dry (oil/water residues). If the electron-
ics come into contact with moisture, this will lead to damages!
2 Clean the system enclosure from the outside, and the protective enclosure
(if present) from the inside with a vacuum cleaner.
3 Clean the (cooled down!) surface of the servo motor to avoid possible heat
congestions.
4 Check the tight fit of all sensors (end position and variable stroke sensors)
Annual servicing/maintenance (after approx. 2000 operating hours)

Prerequisites
 Labeler is separated from the voltage and compressed air.
Instruction
How to perform the annual servicing/maintenance.
Step Approach
1 Check the rewinder for wear. Check all drive timing belts for wear and cor-
rect belt tension. Replace everything that is necessary for the system to
work properly.
2 Check all moving parts for loose connections and possible wear (bearing
clearance).
The servo motor and the type BP motor brake are generally maintenance-
free. Bearings and brakes are subject to wear, and therefore a replacement
of the drive unit is recommended in case of doubt.

Spare parts
Danger due to incorrect spare parts!

Incorrect or defective parts can affect safety and cause personal
injury or damage to the machine.
̶ Use only original spare parts or parts explicitly approved by the
Bluhm Weber Group.
Information on the safety and standard parts of the labeler Legi-Air 6000 can be found in
the documentation folder, along with these operating instructions. The wear parts are
listed there and classified through Service Level ("1" and "2").
We will gladly accept your documentation wishes, and provide you with a corresponding
quote. For this, we kindly ask you to contact your System Consultant.
Wiring and pneumatic plans

The wiring and pneumatic plans are separately documented and included in the scope of
delivery.
Cleaning quick overview
see next page

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
ROLLER-SOLVENT
WALZENREINIGER
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
FÜHRUNGSROLLEN/ GUIDE ROLLERS

AUF- & ABSPULERACHSEN
UN- & REWIND MANDRELS
STEMPELPLATTE /TAMP PLATE

ETIKETTIERER STÜTZLUFT-EINHEIT
LABELER AIR ASSIST ASSEMBLY

Chapter 9 Troubleshooting 40045925 BTA Legi-Air 6000 V2
9. Troubleshooting
The chapter is divided into 2 areas, "Mechanical errors" and "Messages on the display".
The possible causes and their remedies are explained in the following two sections.
Instructions for troubleshooting are only intended for trained professionals.
Mechanical errors
Problem Potential reason Solution

Label liner rips Label roll damaged: Replace label roll.
 Indentations in the label
liner
 Pressure points / damage
to the label roll side.
 The paper width varies
greatly.
Adhesive build-up in the area Remove the adhesive residue
of the peel bar and examine the label roll for
damages caused by the
accumulation of adhesive.
Otherwise replace the roll if
necessary.
Labels cannot be held on the Vacuum generation (venturi) Check the vacuum. If neces-
tamp plate. does not work. sary, increase the pressure,
and if necessary clean or
replace the venturi nozzle.
or Compressed air too low
Permanently bad label posi- Air assist still too high or too
tioning on the tamp plate. low
Air assist tube is incorrectly
positioned.
Inaccurate label positioning The product is not yet / no Check the sensors of the
on the product. longer in the correct labeling conveying system used for
position the identification of products.
Product detector (or possibly Check the sensors and

reflector) loose or vibrating. reattach if necessary
Alternating conveying system Measure and log the speed.
speed (e.g. load-dependent) Contact the supplier of the
conveyor system
Label with unsuitable adhe- Change the label quality.
sive, insufficient initial adhe-
sion force.
... Inaccurate label position- Incorrect parameterization Check time and delay set-
ing on the product. tings of the respective config-
uration parameters (blow...,
extend...)


No or poor air assist function Compressed air too high or Check the of compressed air
(lack of support during the too low setting (approx. 6 bar)
label transfer to the tamp
Internal compressed air tank Check the container in the
leaking pneumatic circuit for leaks
Air assist tube is incorrectly Readjust the air assist, re-
positioned, damaged or not place defective parts, or
connected correctly request a service technician
via the hotline (see page 8).
Quick switch valve defective
Malfunction of the controller. Contact the service hotline
(see page 8).
Label is not dispensed. The print module did not Check the display of the print
receive any data. module. If print data is availa-
ble, it can be seen here.
Incorrect parameterization of Compare the settings using
the print module the printer manual and the
new system checklist (in the
Appendix of this manual)
End position sensor of the Check sensor settings or
home position does not request a service technician
switch. via the Hotline (see page 8).
No triggering from the PLC or Check the received trigger
Product Detector. signal. Cross-check with
[Enter] key
...Label is not dispensed. Optional proximity sensor Check sensor, replace if
does not switch necessary or request a ser-
vice technician via the Hotline
(see page 8).
The desired product cycle The cycle speed of the con- Check the belt speed and the
rate is not reached by the veying system is outside the product spacing, compare the
labeler... specification values with the technical data
of the LA 6000, taking select-
ed application stroke into
account. If possible, reduce
the cycle rate.
Incorrect settings of the Request a service technician
labeler, system cycle times via the Hotline (see Page 8).
too great
The desired product cycle The tamp moves too slowly. Optimize the setup. Request a
rate is not reached by the service technician via the
applicator. Hotline (see Page 8).
The printing process is too Check whether the maximum

slow. print speed is set. Check the
optimization options for the
data processing (e.g. masks
on memory card, avoid true-
type fonts). Please refer to the
printer manual for this.


The applicator starts to label Sensors for the product Check the setting of the
without any apparent reason. detection are loose, vibrate, sensor or request a service
or are influenced by reflec- technician via the hotline (see
tions from the product surface page 8).
Loose cable connections. Check all connections on the
applicator, see page 48.
Incomplete label feed Incorrect print module set- Check the label stock calibra-
tings tion (according to the printer
manual)
Labels are not properly Check paper guidance in print
inserted module (as per printer manu-
al) and on labeler (see page
55).
Motorized rewinder is not Check the functionality of the
switched off by the rewinder dancer arm. If the label liner
dancer arm is tensioned properly, the
rewinder should stop.
The motorized unwinder Check the functionality of the
brake is not switched off by dancer arm. When the ten-
the unwinder dancer arm. sion on the label web is
increased, the label roll must
unwind easily.
No label feed possible Home position sensor is Readjust the sensor, replace
misaligned or defective. if necessary or request a
service technician via the
hotline (see page 8).
Labels are not blown off Quick switch valve defective. Check and replace if neces-
properly from the tamp sary
plate...
Optional proximity sensor Check sensor, replace if

switches too early or not at necessary or request a ser-
all. vice technician via the Hotline
(see page 8).
Labels are not blown off Incorrect parameters for the Check the configurations from
properly from the tamp plate blow-off times page 86>>blow-off time too
early, too short, incorrect
trigger
The blow-off valve does not Check valve, clean and
work. replace if necessary.
Labels are printed out non- Missing synchronization Compare the setting using
stop. through incorrect parameteri- the printer manual and the
zation of the print module. new system checklist
(in the Appendix of this man-
ual)
Poor print quality. Wrong printer setup or wrong Check the instructions for the
print material, contaminants printer manual.
on the printer


Faulty RFID tags are not Incorrect parameterization of Switch off the printer status
rejected by the reject unit, the printer status monitoring monitoring or request a
labeler switches to fault mode service technician via the
hotline (see page 8).

Error messages via display

As soon as there is a fault in the Legi-Air 6000 or if labeling mode was stopped by press-
ing the [Stop] button, the labeler will interrupt the labeling cycle. The vacuum to hold the
label is switched off. The device will switch to the stand-by mode, the green LED on the
control panel will switch off, and the red one will light up. A message whose meaning is
explained below will appear in the 2nd row (status line) of the display:
Error reset
Dangers from actively controlled movements.
RISK OF CRUSHING!
The tamp will be propelled mechanically, and thus develop dan-
gerous forces and high movement speeds.
̶ Maintain a distance from the applicator and remain behind the
safety devices.
Acknowledge the error after it has been resolved by pressing the [Start] button on
the display (cf. page 66) or the pushbutton box (cf. page 64).
The [Start] button of the remote pushbutton box used to acknowledge the error and to re-
start the labeler. To switch the labeler into standby, the following conditions must be met:
 *² The door of the protective enclosure is closed (door contact switch).
 *² The light curtain is cleared.
 *² The emergency stop pushbutton is released.
 The labeler is turned on.
 The [start] button of the remote pushbutton box was pressed.
An independent and uncontrolled on-switching after faults or after an access into the dan-
ger zone will thus be prevented reliably.
This message indicates that one of coprocessors is not responding to the commands from
the master processor which is usually caused by contact problems (typically, if the appli-
cator cable is not plugged in) or if there is a hardware error. Please proceed as follows to
analyze the error: In the programming 003, set the value (from default 000) to 002. The
display shows an error code instead of the E01 error.
Values in the range 50...52 indicate problems with the I/O board, values from 64...65 indi-
cate problems of the applicator-board.

This error message may appear immediately after the on-switching, after a failure of the
internal memory check of all stored parameters (for their completeness). Usually this error
only occurs after a chip reprogramming, or after a reset to factory settings. Possible
cause: In case of a repeated occurrence, problems with loss of data on the memory chip
of the master processor.
The Legi-Air 6000 has a compressed air monitoring system for the input compressed air.
If the input pressure is not between the minimum and maximum pressure, this message
will appear in the display. Possible causes: Error in the compressed air supply. If this is
OK, then there is a defect on one of the internal pressure sensors...
see above E03
This error message appears when the signal of the home sensor is unexpectedly absent,
or the retraction movement of the tamp does not occur within the set time limit (HOME
TIMEOUT, see page 87). Possible causes: Position of the home sensor on the stroke is
displaced, home sensor or cable damaged, stroke mechanically blocked...
This error means that the signal of the home sensor, is still active even after the expiry of
the set time limit (adjustable see programming 054 [for config. 00]; 078 [for 01]; 102 [for
02] 126 [for 03] default value = "100" x 10 ms = 1 s), at the start of the extension move-
ment of the tamp. Possible causes: Stroke is mechanically blocked and cannot extend...
The error only appears when the "trigger status check" is activated (through a correspond-
ing parameterization of the input trigger, see page 77). The message means that the sig-
nal state of the corresponding input has not reverted to a passive state or the trigger
occurred too early. The labeler was therefore unable to detect a signal change (from pas-
sive to active) from the moment of the trigger request. Possible causes: Product sensor is
misaligned or dirty, product is transported too slow or not at all, product spacing too low,
signal from one of the product sensors is active before proximity sensor on the tamp
(if available) is activated...
The message means that a printer error has been detected, or that the print signal was
still active when the print request (start print) was sent to the print module. Possible caus-
es: End of Ribbon, printer is in pause, printer defective...
The error message indicates that the printing of the label has not started within the config-
ured time limit (see page 79) after the print request. Possible causes: no print data availa-
ble, label could not be printed...
If the query "Label on pad" has been activated (see value "+016", page 89), the absence
of the label on the product will be reported.

The message refers to the "Label on tamp" check. This means that sufficient vacuum
could not be generated within the configured timeout (see page 80). Possible causes:
Label not or only partially on the tamp pad >> incorrect air assist setting, leakage in the
area of the tamp pad, problems with vacuum generation [venturi nozzle]...
This message appears if the measured vacuum level falls below the programmed limit af-
ter an initially successful "Label on pad" check (see page 79). Possible causes: Label was
removed from the tamp pad, error in the pneumatic circuit...
This error appears if an unusually weak compressed air maximum during was detected in
the tamp pad during the blow-off phase. The minimum blow-off air is compared with the
stored value of "Programming 014" (default = 3.03 bar). Possible causes: leak, error in the
pneumatic circuit...).
This error appears if an unusually high compressed air maximum during was detected in
the tamp plate during the blow-off phase. The maximum blow-off air is compared with the
stored value of "Programming 15" (default = 3.03 bar). Possible causes: Tamp boreholes
clogged, label sticks to the tamp, contamination or error in the pneumatic circuit...
If the "variable stroke" option has been installed and activated (see page 84), the mes-
sage appears if during the extending movement, the proximity sensor on the tamp pad
could not detect an object within the timeout. Or an object was detected too early at the
beginning of the extension phase. Possible causes: Sensor misaligned or dirty, sensor or
sensor cable defective, inadequate product supply...
Incorrect password input (see pages 75).
Is only displayed if the native barcode reading function is activated (programming 028,
value > "0") and the barcode scanner attached to the tamp has reached the maximum al-
lowed number of successive reading attempts.
This message indicates that the preset maximum number of rejections of unreadable
RFID labels and thus the maximum capacity of the reject unit has been reached.
Or, if programming 028 (value 001-127) is active, the maximum number of successive
reading attempts has been exceeded.

The protective enclosure slide plate (option) could not open within the specified time
(programming 041). Possible cause: Slide plate mechanically blocked, end position sen-
sor "slide plate open" misaligned / defective,...).
The error message E19 depends on the parameterized system. If it is a Legi-Air 6000, a
"Driver Error" is output in the event of an error on the applicator control. Possible cause:
The ready signal of the SES controller could not be set by an error on the servo applica-
tor.
With the other NC labelers, which are equipped with an emergency stop safety relay, this
message appears if the emergency stop circuit was interrupted (e.g. by opening the safety
door switch on the safety guarding and/or the protective enclosure or by actuating
[Compressed Air "OFF"] on the remote pushbutton box.
This message appears when the dancer arm of the rewinder does not move to the correct
work position. Possible causes: The carrier paper is not properly positioned around the
dancer arm and rewinder, it is unable to build up tension or is torn, defects on the rewind-
er motor, sensor or sensor flag...).
*10
The labeler does not detect a label or no transition from gap to label. Possible causes:
Label liner was not inserted correctly, no labels on the label liner... possibly check the set-
ting of the sensor.
If the labeler has been configured for use with a belt applicator, this message is generated
when the LOB (Label On Belt) sensor has not detected the label in time ("in time", means
within the maximum feed length). Possible causes: The label has fallen from the applica-
tor (vacuum fan defective?) or it is still attached to the peel bar, sensor defective, value for
max. feed length too small ...
*10 only applies for Legi-Air 4050AC, Legi-Air 4050WO, Legi-Air 4050WX
An optional strip breakage sensor on the dancer arm indicates a fault as soon as the label
material loses its paper tension. Possible cause: Roll end or tear of the label liner. If no
end or strip breakage of the label material has occurred, check the setting of the sensor.

Status message via display
The following status messages are output on the display before they are "replaced" by a
new status or fault message. For illustration purposes, the messages are explained in the
chronological order that they can appear in during a print-application cycle:
or … or … or
or
...are not error messages, but rather status messages that provide information that a trig-
ger signal is expected. The info number at end of the line specifies the appropriate in-
put at which a trigger is expected. i.e.:
= primary; = secondary; = AUX …input (see also page 77).
If a delay time was also programmed, then after receiving the trigger, the info number will
change to a three digit counter, that counts down the remaining time until the triggering.
Trigger signals can optionally be conditioned (and linked) to the status of one of the other
trigger inputs ("Trigger enable" programming 0264): If the conditioning function is activat-
ed but the corresponding signal is not active, then "TRIGGER DISABLED" is shown in the
second line of the display.
This message appears while the 3-digit info number is being counted down. It displays the
remaining time up to the generation of an error message if the printer does not start to
feed a label within the configured timeout.
This message is displayed during printing if the air assist pushes the label against the
tamp
The vacuum is switched on to hold the label. The current vacuum is displayed in real-time
(no vacuum = 000, "020" to "030" max. vacuum, depending on inlet pressure) for a very
brief moment and is normally barely noticeable to the naked eye. In the event of problems
(displaced label, leaks…), the message is displayed for up to 2.55 seconds before error
E10 (see page 109) is displayed.
This message is displayed if the RFID reject function (see page 89) has been activated
while the reject unit for rejecting the faulty RFID label is active. The cycle then automati-
cally switches to the "WAITING LABEL" phase again to print a new label.

The 3-digit number on the right counts down the time remaining in accordance with the
preset timeout, during which the tamp pad must have left the home position.
If the labeler is fitted with a variable stroke sensor, then if the configuration is correct (see
page 84) the following status message is displayed for the brief pad extension time:
preset timeout, see page 84) before error message E14 (see page 109) is displayed if no
object has been acquired by the var. stroke sensor. For a timeout setting of 255 = infinite-
ly, the countdown display will be omitted.
While the barcode is being read, the digit on the right counts down the time remaining in
accordance with the preset scanning time.
This message requires the option "90° rotating tamp" and an enabled corner wrap applica-
tion. It will appear on the display when the tamp presses the label (around the corner) on-
to the side of the product after labeling the front side. The 3-digit number on the right
counts down the time remaining for the preset timeout.
preset timeout (see page 79), during which the tamp pad must have returned to the home
position after the blow-off process. For a timeout setting of 255 = infinitely, the countdown
display will be omitted.
If the tamp pad reaches the home position the following message will be displayed:
The 3-digit number on the right counts down the time remaining for the SYNC pulse. The
displayed information is only visible with a longer pulse duration setting (see page 88).
The maintenance interval has been reached, the labeler requires repair/maintenance. You
are welcome to order a service technician via the hotline (see page 8).
This text is displayed while the (optional) protective enclosure slide plate on the tamp
pane is being opened.

Chapter 10 Index 40045925 BTA Legi-Air 6000 V2
10. Index
Keywords from A to Z
Access ................................................... 46 EX protection......................................... 15

ACCESS CODE .................................... 76 .................... 112
Adhesive deposits ................................. 98 Feed ...................................................... 11
Air Assist ............................................... 10 Fine-tuning ............................................ 45
Air Blast ................................................. 10 Firmware ............................................... 94
Air filter cartridges ............................... 100 First steps .............................................. 61
Alarm lamp ............................................ 54 Foodstuffs ............................................. 15
.................................. 112 Gap ....................................................... 11
Application modes ................................. 37 Hazardous area..................................... 23
Bad Tag ................................................. 10 ............................... 108
......................... 109 ...................................... 108
Batch operation ..................................... 37 ............................. 108
.................................. 109 Hotline ......................................................9
Blow time ............................................... 86 Inaccurate label positioning ................ 103
Cleaning ................................................ 98 Insert foil ................................................ 59
Compressed-air connection .................. 50 Inserting the label roll ............................ 59
Configuration ......................................... 75 ............................. 109
Connectors ............................................ 48 IP address ............................................. 74
Control buttons ................................ 66, 67 Key shortcuts ........................................ 67
Counter .................................................. 72 Label liner rips ..................................... 103
Cycle...................................................... 10 Label Out ............................................... 11
.............................. 112 ............................. 111
Default ................................................... 10 Labeling mode................................. 62, 63
Delay time ............................................. 12 Leaks ..................................................... 98
Detection ............................................... 11 Legi-Air 4050 ......................................... 30
Diagnostic function ................................ 93 Low Label ........................................ 11, 52
DISPLAY SETTING......................... 71, 73 .................................. 108
......................... 110 Mains voltage connection ............... 49, 51
Drive timing belts ................................. 100 ........................... 109
dusty environment ................................. 15 Menu languages.................................... 71
EC Declaration of Conformity ................ 11 ............................... 108
Emergency ............................................ 14 ............................. 107
.............................. 110 Oil/water residues ......................... 98, 100
Error messages ................................... 107 OPENING DOOR ................................ 112
Error reset ........................................... 107 Operating personnel ............................. 26
Ethernet ........................................... 52, 74 Operation .............................................. 62
EVENT COUNTER................................ 72

Chapter 10 Index 40045925 BTA Legi-Air 6000 V2
Outdoor application ............................... 15 Spare parts .......................................... 101

......................... 108 Stand-by ................................................ 68
Password ............................................... 76 SYNC .................................................... 57
......................... 109 SYNC signal .................................... 87, 88
Place of installation ............................... 46 System decommissioning ............... 64, 66
......................... 112 Tamp-Blow mode .................................. 37
Pneumatics manual ............................. 101 Test function.......................................... 93
Print module .......................................... 30 Transponder .......................................... 13
Print module connection ........................ 54 Trigger ................................................... 13
Print module types................................. 29 TRIGGER .............................................. 77
................................ 108 ............................... 108

Printhead ............................................... 12 Troubleshooting .................................. 107
Product Delay ........................................ 12 Type BP motor brake .......................... 100
Programming mode ............................... 93 Unwinder ............................................... 13
Protection device ................................... 23 .................................... 109
Protective equipment............................. 22 ....................... 109
........................... 112 Venturi ................................................... 13
READY / ALARM................................... 57 Void ................................................. 13, 38
...................................... 111 ............................. 111
Remote pushbutton unit ............ 33, 36, 62 ........................... 111
Rewinder ............................................... 12 ......................... 111
......................... 110 ........................... 111
RFID ...................................................... 12 .................................. 112
RFID reject .......................................... 111 ............................... 111
Scope of delivery ................................... 40 ............................. 111
Service Hotline ........................................ 9 Wiring .................................................. 101
Servomotor .......................................... 100 Wiring diagram .................................... 101
Sleep mode ........................................... 62 ............................. 109

Weber LA 6000 Operating Manual 18.11.2019

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Original instructions

Material number of the documentation 40045925

Version: 01.08.2018 /KRA

2. Safety regulations ............................................................................................... 14

3. Technical Specifications .................................................................................... 27

4. Description of the labeler ................................................................................... 30

Version: 01.08.2018 Page 3 of 114 GB

Figure: Legi-Air 6000 Rear side (LH/RH) ..................................................................................... 34

6. Installation and initial operation ........................................................................ 44

Version: 01.08.2018 Page 4 of 114 GB

System decommissioning ................................................................................................ 64

9. Troubleshooting ................................................................................................ 103

Mechanical errors .......................................................................................................... 103

10. Index ................................................................................................................... 113

Version: 01.08.2018 Page 6 of 114 GB

Purpose and scope of the operating instructions

Version: 01.08.2018 Page 7 of 114 GB

Notes on using the operating instructions

 Work sequences that must be followed are numbered.

 Special information is written in bold and/or with a grey background.

 Messages which are shown in a *²display, will appear in a box:

*² only with an appropriately equipped system

Version: 01.08.2018 Page 8 of 114 GB

 Detailed description of the fault.

Version: 01.08.2018 Page 9 of 114 GB

Explanation of the technical terms

Technical term Explanation

Automatic operation See labeling mode

Bad Tag "Bad Tag" refers to a faulty transponder on an RFID label.

Belt conveyor Conveyor for product transport.

Configuration mode Mode, during which parameters of the applicator configura-

Display Display panel where the status information is shown to the

Version: 01.08.2018 Page 10 of 114 GB

Technical term Explanation

Labeler Application system for the automatic application of labels

Version: 01.08.2018 Page 11 of 114 GB

Technical term Explanation

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

Reset Command to reset the software systems to default values

Rewinder Holder (usually for a 3 inch cardboard core) to rewind the

RFID This acronym stands for Radio Frequency Identification

Version: 01.08.2018 Page 12 of 114 GB

Technical term Explanation

Version: 01.08.2018 Page 13 of 114 GB

Behaviour in case of emergency

What to do in case of an emergency?

General safety regulations

Meaning of the risk levels

This symbol indicates hazardous situations, which will lead to

Version: 01.08.2018 Page 14 of 114 GB

Intended use occurs when …

 the labeler is exclusively used for automatic labeling of moving or stationary

the labeler is used in a non-explosive environment. (No EX protection suitability!).

Version: 01.08.2018 Page 15 of 114 GB

Reasonably foreseeable misuse

Certain risks can emerge in case of an improper use!

Improper use includes:

Conversions and modification of the labeling system

Version: 01.08.2018 Page 16 of 114 GB