FL4050

SEMI-AUTOMATIC LABELING BENCH

USER MANUAL | Version 1.00 - English
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TABLE OF CONTENTS
1. GENERAL INFORMATION......................................................................... 13
1.1. Introduction.................................................................................................................15
1.1.1. Support and maintenance......................................................................................... 15
1.2. General Information...................................................................................................16
1.2.1. Warranty...................................................................................................................... 16
1.2.2. Warranty conditions.................................................................................................. 16
1.2.3. Warranty cancellation............................................................................................... 16
1.2.4. Limitation of liability.................................................................................................. 17
1.2.5. Copyright..................................................................................................................... 17
1.2.6. Software notice.......................................................................................................... 17
1.2.7. Installation requirements......................................................................................... 18
1.2.8. Personnel requirements........................................................................................... 18
1.2.9. Purpose of the manual.............................................................................................. 19
1.2.10. Using the manual..................................................................................................... 20

2. SAFETY REGULATIONS............................................................................. 23
2.1. Normative documents...............................................................................................25
2.2. WEEE disposal..............................................................................................................27

3. WARNINGS AND RISKS............................................................................ 29

3.1. Initial considerations..................................................................................................31
3.2. Behavior in case of emergency.................................................................................31
3.2.1. What to do in case of emergency............................................................................ 31
3.3. Training........................................................................................................................32
3.4. Conventions used in the user manual.....................................................................32
3.4.1. Risk levels.................................................................................................................... 32
3.4.2. Danger and obligation pictograms......................................................................... 33
3.5. Field of use of the equipment...................................................................................35
3.5.1. Intended uses of the equipment............................................................................. 35
3.5.2. Reasonably foreseeable misuse.............................................................................. 35
3.6. Equipment refurbishment and modifications........................................................36
3.7. Safety measures..........................................................................................................36
3.8. Hazard sources............................................................................................................37
3.8.1. Electric components.................................................................................................. 37
3.8.2. Moving parts.............................................................................................................. 37
3.8.3. Pneumatic components (if any)............................................................................... 38
3.8.4. During processing...................................................................................................... 38
3.8.5. Material storage......................................................................................................... 38
3.8.6. Cleaning and maintenance products...................................................................... 38

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 3.9. Residual risks..............................................................................................................39
3.9.1. FL4050 crushing hazard............................................................................................ 39
3.10. Safety labels and identification name plate.........................................................41
3.10.1. FL4050 label overview............................................................................................. 46
3.10.2. Label kit..................................................................................................................... 47
3.10.3. Tracking labels.......................................................................................................... 48
3.10.4. Identification and certification name plates....................................................... 48

4. TECHNICAL SPECIFICATIONS................................................................... 51
4.1. FL4050 general features.............................................................................................53
4.2. Technical specifications.............................................................................................55
4.3. Technical data.............................................................................................................56
4.4. Options and accessories............................................................................................56
4.5. Size and weight...........................................................................................................57
4.5.1. FL4050 semi-automatic labeling bench ................................................................ 57
4.6. Operating environment requirements....................................................................58
4.7. Environmental working conditions..........................................................................58
4.8. Noise.............................................................................................................................58
4.9. Altitude.........................................................................................................................58
4.10. Electromagnetic compatibility................................................................................58
4.11. Lighting.......................................................................................................................58

5. PACKAGING AND TRANSPORTATION..................................................... 61

5.1. Introduction to transportation and installation....................................................63
5.2. Packaging.....................................................................................................................63
5.3. Delivery inspection....................................................................................................63
5.3.1. Identification labels................................................................................................... 64
5.4. Unloading and handling.............................................................................................65
5.4.1. General handling procedures................................................................................... 65
5.5. Unpacking....................................................................................................................66
5.5.1. Tools and PPE required for unpacking.................................................................... 66
5.5.2. Opening the packages.............................................................................................. 66
5.6. What's included in the package................................................................................70
5.6.1. FL4050 labeling bench............................................................................................... 70

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6. UNIT DESCRIPTION AND OPTIONS......................................................... 73
6.1. FL4050 main parts.......................................................................................................75
6.1.1. Electric applicator....................................................................................................... 77
6.1.2. Clamp tamp pad......................................................................................................... 78
6.1.3. FL4050 labeling bench jig.......................................................................................... 79
6.1.4. LCD display control panel......................................................................................... 80
6.1.5. Stack lights.................................................................................................................. 81
6.1.6. Low label sensor......................................................................................................... 82
6.1.7. Counter flanges, support rings and guide rings.................................................... 83
6.1.8. Zebra ZE500 print engine.......................................................................................... 84
6.2. The connector panel...................................................................................................87
6.2.1. FL4050 connector panel............................................................................................ 87
6.2.2. Junction box................................................................................................................ 88
6.3. Signal description.......................................................................................................89
6.3.1. Print engine signals.................................................................................................... 89
6.3.2. Applicator signals...................................................................................................... 90
6.3.3. Interface signals......................................................................................................... 91
6.3.4. Stack lights signals..................................................................................................... 93
6.3.5. Primary product sensor signals.............................................................................. 94
6.3.6. Secondary product sensor signals.......................................................................... 95
6.3.7. Low level sensor signals............................................................................................ 96
6.3.8. Display signals............................................................................................................ 97
6.3.9. WIZ107SR-TTL Ethernet interface . ......................................................................... 98
6.3.10. USB interface ........................................................................................................... 98
6.3.11. Signals for interface from the connector on the junction box.......................... 99
6.4. Buttons and switches...............................................................................................101
6.5. Electrical components.............................................................................................102
6.5.1. Description of the FL4050 labeling bench electronics housing........................ 102
6.5.2. Description of the electrical applicator electronics housing............................ 104
6.6. Description of the FL4050 labeling bench modules.............................................105
6.6.1. CPU board................................................................................................................. 105
6.6.2. 65W 24V 80-264Vac 2xMOPP Class II switching power supply . ...................... 106
6.6.3. WIZ750SR Ethernet module................................................................................... 107
6.6.4. Rewinder motor Picsmd board.............................................................................. 108
6.7. Description of the electric applicator modules....................................................109
6.7.1. 5-valve applicator board.......................................................................................... 109
6.7.2. Electric applicator board..........................................................................................110

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 6.8. Pneumatics description........................................................................................... 111
6.8.1. Description of the pneumatic components of the FL4050 labeling bench......111
6.8.2. Clamp tamp pad pneumatic connections.............................................................114
6.8.3. Air assist.....................................................................................................................115
6.8.4. Compressed air management unit........................................................................116
6.8.5. Solenoid valve assembly for the electric applicator...........................................117

7. INSTALLATION AND SETUP.................................................................... 119

7.1. Preparing for installation.........................................................................................121
7.1.1. Installation requirements........................................................................................ 121
7.1.2. Tools required for installation and maintenance................................................ 121
7.1.3. Installation site.......................................................................................................... 121
7.1.4. Safety area................................................................................................................. 122
7.2. Warnings on installation and commissioning......................................................123
7.2.1. Safety warnings........................................................................................................ 123
7.3. Installation of the FL4050 semi-automatic labeling bench................................124
7.3.1. Foreword.................................................................................................................... 124
7.3.2. Lifting and handling the machine.......................................................................... 124
7.3.3. Installing reel dragging rings.................................................................................. 126
7.3.4. Adjusting the gaskets of the reel support rings and the counter flanges....... 129
7.3.5. Installing the stack lights........................................................................................ 132
7.3.6. Compressed air supply line connection............................................................... 134
7.3.7. Connection to the electrical network.................................................................... 135
7.3.8. PC connection for data management................................................................... 136

8. MACHINE OPERATION........................................................................... 139

8.1. Preliminary information .........................................................................................141
8.1.1. Foreword.................................................................................................................... 141
8.1.2. Environmental working conditions....................................................................... 141
8.1.3. Checkup prior to system startup........................................................................... 141
8.2. Position of the operator..........................................................................................142
8.2.1. Foreword................................................................................................................... 142
8.2.2. Setup.......................................................................................................................... 142
8.2.3. Loading and unloading label reels........................................................................ 142
8.2.4. Labeling with two operators.................................................................................. 143
8.2.5. Labeling with one operator.................................................................................... 143
8.3. Startup of the machine............................................................................................144
8.3.1. Turning on the machine.......................................................................................... 144

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8.4. Loading the reel........................................................................................................145
8.4.1. Introduction.............................................................................................................. 145
8.4.2. Adjusting the slats................................................................................................... 145
8.4.3. Loading the core and label reel............................................................................. 148
8.4.4. Adjusting the rubber guide rings.......................................................................... 153
8.4.5. Labeling bench web path....................................................................................... 155
8.5. Zebra ZE500 print engine.........................................................................................156
8.5.1. Introduction.............................................................................................................. 156
8.5.2. Print engine control panel...................................................................................... 157
8.5.3. Thermal transfer labels or direct thermal printing?.......................................... 158
8.5.4. Loading the ribbon.................................................................................................. 158
8.5.5. Loading the label reel.............................................................................................. 162
8.6. Using the counter flanges.......................................................................................168
8.7. Machine start-up.......................................................................................................170
8.7.1. Setting the number of operators........................................................................... 170
8.8. Processing cycle with two operators.....................................................................172
8.8.1. Machine reservation by the operator................................................................... 172
8.8.2. Scanning the product.............................................................................................. 173
8.8.3. Product labeling....................................................................................................... 175
8.9. Processing cycle with single operator...................................................................178
8.9.1. Scanning the product.............................................................................................. 178
8.9.2. Product labeling....................................................................................................... 181
8.10. The various modes of the labeling bench............................................................184
8.10.1. Machine off-line (Stand-by)................................................................................... 184
8.10.2. Machine idle............................................................................................................ 184
8.10.3. Machine alarm........................................................................................................ 184
8.11. Alarm management................................................................................................185
8.11.1. Introduction............................................................................................................. 185
8.11.2. Troubleshooting..................................................................................................... 185
8.12. Replacing the label reel..........................................................................................186
8.13. Changing label size..................................................................................................187
8.13.1. Introduction............................................................................................................. 187
8.13.2. How to change the clamp tamp pad................................................................... 187
8.13.3. Calibrating the print engine................................................................................. 200
8.13.4. Air assist adjustment............................................................................................. 203
8.14. Language setup...................................................................................................... 206
8.14.1. Introduction............................................................................................................ 206
8.14.2. How to change the language . ............................................................................. 207
8.15. Turning off the machine........................................................................................ 209
8.16. Temporary shut down .......................................................................................... 209

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 9. MAINTENANCE....................................................................................... 211
9.1. Introduction to routine maintenance....................................................................213
9.2. FL4050 routine maintenance..................................................................................213
9.2.1. Cleaning the labeling bench................................................................................... 213
9.2.2. Cleaning the jig......................................................................................................... 214
9.2.3. Cleaning the low label sensor................................................................................ 215
9.2.4. Cleaning the rollers................................................................................................. 216
9.2.5. Cleaning the spindles and the reel dragging rings............................................. 217
9.2.6. Cleaning and maintenance of the clamp tamp pad........................................... 219
9.3. Compressed air management unit maintenance............................................... 220
9.3.1. Access to the filter regulator.................................................................................. 220
9.3.2. Discharging condensation from the filter regulator.......................................... 221
9.3.3. Replacing the filter cartridge................................................................................. 222
9.3.4. Pressure adjustment............................................................................................... 223
9.4. Print engine maintenance...................................................................................... 224
9.4.1. Cleaning the external parts.................................................................................... 224
9.4.2. Cleaning the media compartment........................................................................ 224
9.4.3. Cleaning the printhead and the platen roller...................................................... 225
9.4.4. Replacing the printhead......................................................................................... 227
9.4.5. Replacing the platen roller..................................................................................... 229
9.5. Routine maintenance plan......................................................................................231
9.6. Introduction to extraordinary maintenance........................................................232
9.7. FL4050 extraordinary maintenance...................................................................... 233
9.7.1. Access to module mounting points........................................................................ 233
9.7.2. Replacement of the LCD display............................................................................234
9.7.3. Replacement of the low label sensor.................................................................... 236
9.7.4. Replacement of the stack lights............................................................................. 239
9.7.5. Replacement of the unwinder and rewinder....................................................... 242
9.7.6. Replacement of the paper guide rollers............................................................... 246
9.7.7. Replacement of the print engine............................................................................ 248
9.7.8. Replacement of the applicator............................................................................... 251

10. USER MANUAL REVISIONS.................................................................. 257

10.1. User manual revisions............................................................................................259

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11. DIAGNOSTICS AND TROUBLESHOOTING........................................... 265
11.1. FL4050 diagnostics..................................................................................................267
11.1.1. Error management.................................................................................................. 267
11.1.2. Faults and malfunctions........................................................................................ 271
11.2. LCD display diagnostics . .......................................................................................275
11.2.1. Faults, malfunctions and common problems.................................................... 275
11.3. Zebra ZE500 print engine diagnostics................................................................. 277
11.3.1. Error messages....................................................................................................... 277
11.3.2. Printing problems.................................................................................................. 283
11.3.3. Ribbon problems................................................................................................... 287
11.3.4. Communication problems.................................................................................... 289
11.3.5. Miscellaneous problems....................................................................................... 290
11.4. Filter regulator diagnostics...................................................................................291
11.4.1. Faults and malfunctions........................................................................................ 291

12. ELECTRICAL AND PNEUMATIC DIAGRAMS . ...................................... 293

12.1. Diagrams for the FL4050........................................................................................295
12.1.1. Interconnection wiring diagram........................................................................... 295
12.1.2. FL4050 wiring diagram.......................................................................................... 296
12.1.3. AE4050 pneumatic diagram................................................................................. 297

13. SPARE PARTS......................................................................................... 299

13.1. AE4050-LD spare parts catalog.............................................................................301

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1. GENERAL INFORMATION CAPITOLO
CHAPTER 1
INFORMAZIONI
GENERAL INFORMATION
GENERALI
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 1.1. Introduction
Welcome to the world of WEBER MARKING SYSTEMS ITALY! You have just purchased one of
our high-quality labeling products.
WEBER MARKING SYSTEMS ITALIA is the industry leader in automatic label application
systems for both reliability and safety.
We recommend that the installation is carried out by one of our partners for the proper
operation of the equipment. All WEBER MARKING SYSTEMS ITALIA equipment parts have
been designed and manufactured to ensure the best performance and to maintain a
high-level quality and reliability over time. We recommend reading this document to take
advantage of all the features of the equipment and to use original spare parts.
WEBER MARKING SYSTEMS ITALIA equipment is compliant with the Machinery Directive
2006/42/EC limited to the essential safety requirements stated on the Declaration of
Conformity or Incorporation, depending on the product purchased.

1.1.1. Support and maintenance

Please contact our technical support department for support and maintenance of WEBER
MARKING SYSTEMS ITALIA products. Our centralized warehouse is well stocked with spare
parts, available for delivery, in most cases, within 24 hours after placing the order.
To receive assistance, you are required to have the following information:
• unit and display serial numbers
• fault description: provide all details
• exact circumstances under which the error occurs

Original language of the manual: Italian

WEBER MARKING SYSTEMS ITALIA

Offices: Via Sant’Andrea 11/b | 20008 Bareggio (MI)
Warehouse: Via Redipuglia 8/b | 20008 Bareggio (MI)
T.: +39 02 80898225
web: www.webermarking.it | e-mail: info@webermarking.it

Version 1.0 2 March, 2022

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 1.2. General Information
1.2.1. Warranty
All WEBER MARKING SYSTEMS ITALIA equipment is guaranteed for 12 months from the
date of invoice, unless otherwise agreed in writing. The warranty covers all defects in
materials and workmanship, and provides for replacement of parts or repair of defective
parts exclusively on our behalf.
The warranty, which is subject to WEBER MARKING SYSTEMS ITALIA decision, does not
foresee the assistance of our technicians on the installation site of the equipment, nor its
disassembly from the system.
The following are excluded from the warranty:
• faults caused by incorrect use or assembly
• failures caused by external factors
• failures caused by neglect or poor maintenance

The warranty does not include maintenance which, on request, will be carried out on the
basis of the prices and conditions in force at the time of the service.

1.2.2. Warranty conditions

Warranty conditions are in accordance with the general terms and agreements between
the manufacturer and the customer at the time of purchase. The warranty of this system
is subject to the obligation of the customer and user to follow all instructions and
recommendations described and explained in the user manual. Particular attention should
be given to maintenance and operating procedures.
It is therefore recommended to contact the manufacturer if the procedure is not described
in the manual.
We strongly recommend that all personnel involved in the installation, operation and
maintenance of the labeling machine have read and understood this manual before
performing any task.

NOTE:
If the device is transferred to a third party, all documentation must be
delivered with the device.

1.2.3. Warranty cancellation

The warranty will be voided with immediate effect in case of arrears or other contractual
defaults, in case of damage caused by misuse, mishandling, accident and other causes not
attributable to normal operating conditions, in case of use of non-original consumables
or spare parts, tampering and alterations or improper servicing, in case of vandalism or
damage caused by atmospheric events, if the serial number is tampered or erased, or if the
equipment is used for purposes other than those indicated in this user manual.
Repairs made under warranty do not interrupt the warranty period.
The above warranty is exclusive and WEBER MARKING SYSTEMS ITALIA disclaims all other
warranties, whether written, spoken, or implied.
Subject to the warranty set forth above, WEBER MARKING SYSTEMS ITALIA will not be liable
for any other damages, including damages for any use or misuse of the product.

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 1.2.4. Limitation of liability
All of the information and recommendations in this manual, as well as the maintenance of
the equipment, have been compiled considering all applicable norms and regulations, the
latest technological developments, and our many years of knowledge and experience.
WEBER MARKING SYSTEMS ITALIA declines any liability for damage due to:
• non-compliance with the operating instructions
• improper use of the system
• use by untrained personnel
• modifications to the system not approved by the manufacturer
• use of non-approved spare parts

The obligations agreed upon in the supply contract, the general terms and conditions of
business, as well as the manufacturer’s terms and conditions of supply and the applicable
legal provisions in force at the moment the contract is concluded, shall apply.

1.2.5. Copyright
All rights reserved. No part of this manual may be reproduced in any form without the
express written permission of WEBER MARKING SYSTEMS ITALIA.
WEBER MARKING SYSTEMS ITALIA reserves the right to make any changes to parts, details,
and accessories that it deems necessary to improve the equipment or for constructive
or commercial reasons, at any time and without obligation to promptly update this
publication.
Every care has been taken in compiling and verifying the documentation to make this
manual as complete and understandable as possible.

1.2.6. Software notice

Please observe the following guidelines when using the software:
• the user may not reverse engineer, decompile or disassemble the
software, except as specifically permitted by applicable law
• the software product is licensed with the equipment as a single
integrated product
• the user may permanently transfer all rights granted by the agreement,
only as part of a sale of the equipment, provided that the user does
not retain any copies, sells the entire software product (including
all components, any media and printed materials, any updates, this
agreement and, if applicable, the Certificate of Authenticity), and
the transferee agrees to the terms of this agreement. If the software
product is an upgrade, any sale must include all prior versions of the
software product
• title and all software copyrights (including but not limited to any
images, animations, and text accompanying the software), any
accompanying printed material, and any copies of the software are
owned by WEBER MARKING SYSTEMS ITALIA. The product is protected
by copyright laws and international treaty provisions. The user may not
reproduce the printed material accompanying the software

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 1.2.7. Installation requirements
Specific conditions must be met before the equipment can be installed:
• a closed and clean installation area
• a suitable support where to fix the equipment
• a low vibration environment
• adequate lighting
• no direct sunlight or heat radiation
• the unit must not operate in environments with electrostatic or
magnetic fields
• adequate power supply, according to technical specifications
• compressed air (where applicable)

1.2.8. Personnel requirements

Any operations on the equipment must be performed by properly trained personnel only.
Therefore, it is necessary that personnel, in general:
• has the minimum age allowed by law to work and operate on the
equipment
• has received appropriate training
• is aware of emergency and evacuation procedures
• is familiar with first aid procedures
• has read and understood the safety warnings and instructions
regarding the start-up, operation and maintenance of the equipment

In general, the labeling machine should only be used by people who have received
complete training. Trainees may only perform operations under the supervision of
experienced personnel.
The user manual makes distinction between personnel who may only operate the unit and
personnel who may also perform maintenance and repair operations.
THE OPERATOR can carry out processing operations, such as:
• start and stop processing
• load the reels of material to be processed
• unload the reels of processed material
• carry out daily cleaning operations, according to scheduled
maintenance (chapter 9)

The TECHNICIAN is a person with a higher education (mechanic, electrician, etc.), trained
by WEBER MARKING SYSTEMS ITALIA or one of its partners, who carries out installation,
maintenance and repair operations on the equipment and its components.

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 1.2.9. Purpose of the manual
This document has been prepared for the installer, the serviceman and the user of the unit.
It provides all the information needed to:
• handle correctly the machine (pack and unpack in safety conditions)
• properly install the machine
• use the machine under safety conditions
• thoroughly understand operation procedures and any limitations of
the equipment
• perform scheduled maintenance
• dispose of the unit safely and in compliance with the regulations in
force to protect the health of workers and the environment

This user manual is part of the equipment and must be accessible to the personnel in
charge of its use and maintenance.
Following the guidelines in this user manual helps prevent hazards, reduce repair costs and
minimize downtime. It also increases the reliability and longevity of the system.
The operating instructions apply to the system mentioned on the cover and footer.
The user manual must be accessible at all times while the equipment is in operation. All
instructions in the document must be read, understood, and followed by all personnel
involved with the system.
For clarification purposes, illustrations may show the machine without guards. The
descriptions and illustrations in this publication are not to be considered as binding.

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 1.2.10. Using the manual
The following is a detailed explanation of the writing and representation styles used in this
manual
• Buttons and switches that must be pressed are indicated in square
brackets, in uppercase and boldface lettering.
Example: Press the [START] button to confirm

• The commands and entries available on the LCD display are indicated
with a font characteristic of the display.
Example: WAITING LABEL

• Machine status modes are indicated in upper case and boldface

lettering.
Example: The machine is in STAND-BY

• The work sequences are numbered or described step by step in the

captions
Example: 1. Disconnect the power plug
2. Remove the protective guard

Example: Picture 1 How to access the filter regulator - Step 1

• Notes are at the bottom of texts

Example: NOTE:
If the labeling mode...

• Relevant information in the texts is highlighted in bold

Example: Example of relevant information

• All illustrations are numbered in sequence (Figure 1)

• The reference numbers of the illustrations are inserted in the text

between square brackets
Example: Tighten the two screws [1] shown in the picture.

• Safety instructions are on the outer side of the page. At the bottom of
the column, when it applies, the machine configuration shown in the
picture

• In some cases, protective guards or safety devices are not shown to

facilitate the comprehension of the picture

• In some cases, manuals have been written for an entire series of

machines. Considering the different configurations, it is possible that
the example pictures may differ from the equipment as only one
machine is taken as an example

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2. SAFETY REGULATIONS CAPITOLO
CHAPTER 21
INFORMAZIONI
SAFETY REGULATIONS
GENERALI
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 2.1. Normative documents
During the design and production of the equipment, WEBER MARKING SYSTEMS ITALIA
has adopted construction criteria and carried out tests to obtain results that meet the
requirements indicated by the legislative prescriptions and by the directives that regulate
the introduction and the distribution of products on the market. The main reference
directives and standards are indicated below.

Table 1 Reference directives

Directive Description
2006/42/EC Machinery Directive - on machinery, and amending Directive
95/16/EC
2014/35/EU Low Voltage Directive - harmonisation of the laws of the Member
States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits
2014/30/EU Electromagnetic Compatibility (EMC) Directive - harmonisation
of the laws of the Member States relating to electromagnetic
compatibility
89/391/EEC Framework Directive on Safety and Health at Work -
implementation of measures to encourage improvements in safety
and health at work
Dlgs 81/2008 Testo unico sulla salute e sicurezza sul lavoro (safety and health at
(Italy) work)
Regulations National regulations
in force in the
country where
the equipment is
installed

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 Table 2 Reference norms and standards

Reference norm Description

or standard
EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic
standards - Emission standard for industrial environments
EN 55016-1-2 Specification for radio disturbance and immunity measuring
apparatus and methods - Part 1-2: Radio disturbance and
immunity measuring apparatus - Coupling devices for conducted
disturbance measurements
EN 55016-2-3 Specification for radio disturbance and immunity measuring
apparatus and methods Part 2-3: Methods of measurement of
disturbances and immunity - Radiated disturbance measurements
EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic
standards - Immunity for industrial environments
EN 61000-4-2 Electromagnetic compatibility (EMC) Part 4-2: Testing and
measurement techniques - Electrostatic discharge immunity test
EN 61000-4-3 Electromagnetic compatibility (EMC) - Part 4-3: Testing
and measurement techniques - Radiated, radio-frequency,
electromagnetic field immunity test
EN 61000-4-4 Electromagnetic compatibility (EMC) Part 4-4: Testing and
measurement techniques - Electrical fast transient/burst immunity
test
EN 61000-4-5 Electromagnetic compatibility (EMC) Part 4-5: Testing and
measurement techniques - Surge immunity test
EN 61000-4-6 Electromagnetic compatibility (EMC) Part 4-6: Testing and
measurement techniques - Immunity to conducted disturbances,
induced by radio-frequency fields
EN 61000-4-11 Electromagnetic compatibility (EMC) Part 4-11: Testing and
measurement techniques - Voltage dips, short interruptions and
voltage variations immunity tests for equipment with input current
up to 16 A per phase
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
EN 55011 (class A) Industrial, scientific and medical equipment - Radio-
frequency disturbance characteristics - Limits and methods of
measurement

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 2.2. WEEE disposal
The Law of 3 May 2019, no. 37 “Disposizioni per l’adempimento degli obblighi derivanti
dall’appartenenza dell’Italia all’Unione europea” (provisions for the fulfilment of obligations
arising from Italy’s membership of the European Union), which became effective on 26 May
2019, by means of Article 19, made some amendments to the Legislative Decree 49/2014, in
order to align the national WEEE regulations with the Directive 2012/19/EU.

System components do not have any particular disposal issues.

Table 3 Material division

Type Examples
Electrical and electronic Boards, power supplies, motors, electrical cables
components
Mechanical parts (iron, steel, Plates, gears, small parts and fixing materials
aluminum, copper, brass)
Plastic/rubber Polycarbonate counter flanges, air hoses, gaskets,
transmission belts, small parts

Disposal of electronic boards

It is recommended to use specialized e-waste disposal companies in accordance with local/
national regulations.

English | Version 1.0 | FL4050 | 27

3. WARNINGS AND RISKS CAPITOLO
CHAPTER 31
INFORMAZIONI
WARNINGS AND
GENERALI
RISKS
Page intentionally left blank
 3.1. Initial considerations
This chapter describes all the precautions that must be taken to avoid damage/risks to
health and the environment arising from improper use of the equipment, both during
processing operations and during maintenance.
Although various devices and mechanisms have been implemented to eliminate or limit the
sources of danger associated with use or maintenance, some residual risks may still
exist. WEBER MARKING SYSTEMS ITALIA cannot be held responsible in case of incorrect
or improper use of the equipment, modifications and/or changes made to the equipment
without prior written authorization from the manufacturer.
Only trained and qualified personnel are permitted to operate and maintain this
equipment.
Improper use, incorrect maintenance, or modifications made to the equipment
without the written approval of WEBER MARKING SYSTEMS ITALIA may cause a
hazardous situation. WEBER MARKING SYSTEMS ITALIA disclaims all liability for
damage caused to persons or property resulting from improper use.

3.2. Behavior in case of emergency

All personnel involved in the installation, operation, and maintenance of the equipment
should be familiar with the location of safety equipment, with emergency procedures, with
accident reporting, and with evacuation and first aid procedures.

3.2.1. What to do in case of emergency

Below is a list with the emergency procedures:
• immediately disconnect the labeler from the compressed air and
power supply in case people or body parts are trapped between the
moving parts of the machine. The same procedure must be followed in
case of trapped objects
• immediately provide assistance to the injured person. It is essential to
observe all applicable safety rules to prevent further injury to persons
• seek for medical assistance
• eliminate all causes of the accident

English | Version 1.0 | FL4050 | 31

 3.3. Training
Training of personnel involved in equipment installation, use and maintenance operations
is mandatory. WEBER MARKING SYSTEMS ITALIA provides the necessary training to
dealers, integrators and resellers, who must train technicians for service and extraordinary
maintenance operations, and operators for the use and ordinary maintenance of the
equipment.

3.4. Conventions used in the user manual

Safety warnings provide text and graphical information about the hazards involved in using
the equipment.
In the documentation (such as user manuals), safety warnings are preceded by key words
that indicate the risk level.
Adhesive labels are affixed directly on the equipment, indicating any hazardous points or
warnings that must be observed, and certifying the equipment. For safety reasons, it is
forbidden to remove them. Refer to paragraph 3.10 for positioning.

3.4.1. Risk levels

The following is a list of the terminology used in this manual and its meaning to indicate the
level of risk during installation, operation and maintenance procedures. Always observe all
safety precautions to prevent personal injury.
Pay attention to the operating area of the equipment - that is, the area around the
equipment where the health and/or safety of people is at risk.

Table 4 Meaning of risk levels

Terminologia Descrizione
DANGER Condition of imminent risk which can lead to serious injuries or death

WARNING Potential risk condition which can lead to serious injuries or death

Potential hazardous condition which can lead to medium or minor

CAUTION
personal injury or economic damage to the machine or property
Potential risk condition which may cause economic damage to the
NOTICE
machine or property

32 | FL4050 | Version 1.0 | English

 3.4.2. Danger and obligation pictograms
Pictograms are found on the equipment and in the manuals to draw the operators’
attention to the hazards and to the obligations. The following pictograms may be found on
equipment and/or documentation provided by WEBER MARKING SYSTEMS ITALIA.

Table 5 Conventional hazard pictograms

Pictogram Description

Indicates a hazard of possible contact with electricity

Indicates a generic hazard and requires additional signage to provide

further information about the risk

Indicates a hazard due to toxic materials

Indicates a possible crushing hazard due to mechanical locking parts

Indicates a dragging hazard caused by counter-rotating rollers

Indicates a hot surface hazard

Indicates a sharp object hazard (blades, knives, sharp edges)

Indicates a hazard due to magnetic fields

Indicates a hazard due to flammable material

Indicates a danger due to an obstruction at ground level

Indicates a hazard due to suspended loads

Indicates a hazard due to forklifts and other industrial vehicles

English | Version 1.0 | FL4050 | 33

 Table 6 Conventional obligation pictograms

Pictogram Description

It is mandatory to read the instructions

It is mandatory to disconnect the power supply

It is mandatory to disconnect machinery before servicing or repairing

It is mandatory to carry out the grounding

It is mandatory to wear eye protection

It is mandatory to wear safety footwear

It is mandatory to wear safety gloves

It is mandatory to wear protective clothing

34 | FL4050 | Version 1.0 | English

 3.5. Field of use of the equipment
The equipment has been designed for automatic labelling in the industrial field to identify
and trace materials and goods in production and logistic processes and for the application
of informative and/or decorative labels. Depending on the model, the labeler can be
integrated with options and installed in pre-existing work lines.
WEBER MARKING SYSTEMS ITALIA declines all liability deriving from improper use of
the equipment.

3.5.1. Intended uses of the equipment

The reliability and operational safety of the equipment is guaranteed only when used as
intended. Failure to follow the points described in the tables below may result in property
damage and personal injury and relieves the manufacturer from all liability.

Table 7 Intended uses of the equipment

Intended uses
The unit must be used exclusively for automatic labeling of mobile or stationary objects
Manual servicing should only be carried out after the unit has been shut down
The unit must be used only with the products and labels specified and agreed upon by
the dealer, integrator or vendor with the customer
The unit must be used only in a non-explosive environment. It is not intended for use in
explosion-protected locations
The unit must not come into direct contact with food
The unit can be used in harsh industrial environments if protective measures are taken
such as additional ventilation in the housing to protect against dust or airborne particles
In the case of brackish or similar environments, the protective housing must be made of
stainless steel
The unit must be used only in an industrial environment
The unit cannot be used for outdoor applications
The unit can be used if the technical specifications described in chapter 4 are met
Protection systems must not be bypassed or disabled
The unit can be used if the conditions and operating procedures described in the user
manual are met
Unit malfunctions may affect safety and must be reported and corrected immediately
only by properly trained and qualified personnel
Ordinary maintenance must be carried out properly as per chapter 9 by authorized
technicians
The unit may be used only if no faults or errors are detected
The unit must not be modified without the written consent of the manufacturer
All personnel involved in the installation, use and maintenance must have read and
understood the user manual
All personnel involved in installation, use and maintenance must have received
appropriate training (paragraph 3.3)

3.5.2. Reasonably foreseeable misuse

Any use other than that specified in subparagraph 3.5.1 or any additional use is considered
improper use. Damage caused by improper use is the sole responsibility of the user.
Some hazards may arise from improper use of the equipment.

English | Version 1.0 | FL4050 | 35

 3.6. Equipment refurbishment and modifications
The product warranty is immediately void in case of unauthorized modifications and
alterations. Any modification must be approved and authorized by WEBER MARKING
SYSTEMS ITALIA or its partners with written consent. The same applies to interventions
and changes to the control system and software, as well as changes to the parameters of
the control devices not described in the user manual.
The electromagnetic behavior of the equipment may be affected by modifications or
alterations of any kind.
Do not make any changes or additions to the equipment without consulting the
manufacturer or one of its partners.

3.7. Safety measures

The following are the main safety precautions adopted to protect users. The two tables
illustrate those relating the manufacturer and the user.
Table 8 Safety measures (manufacturer)

Description
Electrical housing cover, removable using mechanical equipment, minimum thickness of
0.8 mm
Remote operation of the equipment
Display touch screen
Labels and tags located on the exterior and interior of the equipment indicating hazard
areas and identification and certification

Table 9 Safety measures (user)

Description
Safety must be guaranteed at all times for all users working with the unit
The technical data and information on installation, connection, ambient and operating
conditions must be observed
Unit-specific safety precautions must be observed
The use of personal protective equipment where required must be adhered to
Hazard zone signs and labels must be replaced if damaged or lost
Precautions indicated on warning labels must be observed
Trainees or apprentices must always work under the supervision of an experienced
person
All work on electrical parts must be carried out in a workmanlike manner and only by
qualified electricians
All unit malfunctions must be corrected as soon as possible by properly trained
personnel or authorized technicians
Qualified personnel must be trained in the use of the integrated control before
configurations are allowed

36 | FL4050 | Version 1.0 | English

 3.8. Hazard sources
3.8.1. Electric components
Hazard due to direct or indirect contact with live parts WARNING
DANGER OF DEATH!
Contact between people and energized components can result in death. Before working
on the electrical equipment, turn the equipment off from the main switch and lock
it to prevent unintentional reactivation. If possible, disconnect the equipment from
the power supply.
The parts of the unit that are energized are:
• the connector panel
• the electric housing

Be sure to observe the following points when operating or servicing this equipment:
• before using the equipment, make sure that the covers of the electrical
parts are fitted or have not been removed
• when the unit is turned on, do not reach into the above areas with your
hands or other parts of your body or with metal objects
• all work on electrical parts must be carried out in a workmanlike
manner by specialized electricians
• the electrical parts of the labeler should be checked regularly. If
necessary, fix loose connections and replace damaged cables
• during maintenance operations, turn off the unit and wait a few minutes
before removing the covers of the electrical housing. Capacitors in the
circuit may carry residual voltage
• if the control and command devices are not properly connected,
disturbances and/or damage to the equipment may occur during
operation. This may affect safety
• always ground the equipment

The equipment, for voltages and currents used, is included in the Low Voltage Directive.

3.8.2. Moving parts

Hazards due to moving parts
RISK OF DRAGGING AND CRUSHING!
The rotating parts of the unit, such as the rewinder of the liner material, the liner brake, CAUTION
and the cylinders of the transmission group, are driven by a motor that will stall if an
obstruction is detected.
Equipment parts subject to movement are:
• the towing unit
• the unwinder
• the rewinder
• linear or rotary applicator drives

Pay attention to the following when using and servicing the equipment:
• before starting up the equipment, make sure that no objects are
blocking the movement of moving parts
• do not put hands or other parts of the body in the areas of the
equipment subject to movement
• be careful when loading and unloading material because the motors
are potentially active
• wear only tight-fitting, tear-resistant, short-sleeved clothing
• do not wear ties, bracelets, watches or similar items

English | Version 1.0 | FL4050 | 37

 3.8.3. Pneumatic components (if any)
CAUTION Hazard due to residual energy in pneumatic components
RISK OF INJURY!
Compressed air hoses, exhaust valves, and moving parts of equipment can cause injury.
• Before connecting the compressed air, check all pneumatic
components for tightness and secure them if necessary
• The pneumatic system must be emptied during maintenance

3.8.4. During processing

CAUTION
Hazard due to reel breakage during operation
RISK OF INJURY!
Material tension fatigue due to the application of additional weights (label rolls, tools, etc.)
on the system can tear the material.
• Do not use or place additional weight on the system

CAUTION Hazard due to sharp corners and edges

RISK OF INJURY!
Sharp edges and corners can cause abrasions and cuts on the skin. Always keep the work
area clean.
The sharp parts of the equipment include:
• unwinder reel support blades
• rewinder reel support blades

Pay attention to the following when using and servicing the machine:
• be careful when working near sharp edges and corners
• use protective gloves whenever possible

CAUTION
Risk of tripping over connecting cables
RISK OF FALLING!
It is possible to trip over connecting cables for power, compressed air, data, and signals.
• Lay cables in a safe and hazard-free manner, using cable trays
whenever possible.

3.8.5. Material storage

CAUTION Hazard due to highly flammable material in storage
FIRE HAZARD!
Stored films and labels can be easily ignited. Risk of injury from fire and released fumes.
• Keep stored material away from heat sources and open flames

3.8.6. Cleaning and maintenance products

CAUTION
Health hazards from improper use of lubricants and detergents
HEALTH HAZARD!
• Improper use can lead to health risks
• It is necessary to follow the instructions on the safety data sheets
of the manufacturers of lubricants and detergents used during
maintenance and cleaning

38 | FL4050 | Version 1.0 | English

 3.9. Residual risks
The AE450-LD semi-automatic labeling bench has been designed and manufactured in
accordance with the 2006/42/EC Machinery Directive. Although WEBER MARKING SYSTEMS
ITALIA has used every means to reduce hazards through design, safety devices and covers,
there is still a residual risk. Knowing about residual risks helps prevent accidents. Always
observe the safety warnings in all chapters of the user manual.

3.9.1. FL4050 crushing hazard CAUTION

The area shown in the figure is considered to be a potential crushing hazard [1] during
machine operation. Avoid putting hands or other body parts in the indicated area. In any
case, the jig has been designed to rise in the event of an obstruction during the operation
of the applicator. The marked moving parts [2 and 3] do not constitute a hazard. However,
avoid wearing loose clothing, ties, bracelets, watches, etc.

1 2 3

Picture 1 FL4050 crushing hazard

1. Applicator
2. Rewinder
3. Unwinder

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 39

 CAUTION As a safety measure, the jig [4] is designed to rise in case an obstruction is encountered
during the operation of the applicator.

Picture 2 FL4050 crushing hazard

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

40 | FL4050 | Version 1.0 | English

 3.10. Safety labels and identification name plate
Each FL4050 comes with safety labels that inform the user of residual risks, and the
product identification and certification name plate.
It is forbidden to remove any labels. The following pictures illustrate the position of the
labels on the FL4050 semi-automatic labelling bench.

ATTENTION
Crush hazard
Moving parts above.
Keep hands and fingers
clear during operation.
Disconnect power supply
and compressed air before
inspection, adjustment,
servicing or maintenance.

Weber Marking Systems GmbH

Maarweg 33
D-53619 Rheinbreitbach
Model:
S/N:
FL4050
000XXXXX
RH
Tel.: +49(0)2224/77080
www.webermarking.de
Equipment: 40058960
Date: 07/2021
Power rating: 90-263VAC - 150W MAX

Configuration in
the picture: FL4050
Picture 3 FL4050 safety label position - Front view right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 41

 ATTENTION
Crush hazard
Moving parts below.
Keep hands and fingers
clear during operation.
Disconnect power supply
and compressed air before
inspection, adjustment,
servicing or maintenance.

Picture 4 FL4050 safety label position - Top view

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

42 | FL4050 | Version 1.0 | English

 WARNING
Read and understand
the operator’s manual
and all other safety
instructions before
using this equipment.

DANGER
Electric shock hazard
Switch OFF and disconnect
the equipment
from the power supply
before inspection,
adjustment, servicing
or maintenance.

Picture 5 FL4050 safety label position - Rear view

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 43

 Picture 6 FL4050 safety label position - Rear view without the rear protection panel

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

44 | FL4050 | Version 1.0 | English

Picture 7 FL4050 safety label position - Internal view of the electronics housing

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 45

 3.10.1. FL4050 label overview
Table 10 Overview of the safety labels

Label Quantity Size

1 b = 65 mm
ATTENTION
Crush hazard
Moving parts above.
Keep hands and fingers
clear during operation.
Disconnect power supply
and compressed air before
inspection, adjustment,
servicing or maintenance.

2 b = 65 mm
ATTENTION
Crush hazard
Moving parts below.
Keep hands and fingers
clear during operation.
Disconnect power supply
and compressed air before
inspection, adjustment,
servicing or maintenance.

1 b = 65 mm
WARNING
Read and understand
the operator manual
and all other safety
instructions before
using this equipment.

1 b = 65 mm
DANGER
Electric shock hazard
Switch OFF and disconnect
the equipment
from the power supply
before inspection,
adjustment, servicing
or maintenance.

1 b = 20 mm

1 b = 20 mm

1 Ø = 10 mm

1 Ø = 20 mm

1 b = 122 mm
Weber Marking Systems GmbH Model: FL4050
Maarweg 33
D-53619 Rheinbreitbach
Tel.: +49(0)2224/77080 S/N: 000XXXXX
www.webermarking.de
Equipment: 40058960
Date: 07/2021
Power rating: 90-263VAC - 150W MAX

46 | FL4050 | Version 1.0 | English

 WARNING WARNING
Read and understand Read and understand
the operator manual the operator manual
and all other safety and all other safety
instructions before instructions before
using this equipment. using this equipment.

RH
RH

AE4050-LD / FL4050
AE4050-LD / FL4050
DANGER DANGER
Electric shock hazard Electric shock hazard
Switch OFF and disconnect Switch OFF and disconnect
the equipment the equipment
from the power supply from the power supply
before inspection, before inspection,
adjustment, servicing adjustment, servicing
or maintenance. or maintenance.

AE4050-LD AE4050-LD
ATTENTION ATTENTION
Crush hazard Crush hazard
3.10.2. Label kit

Moving parts above. Moving parts above.

Keep hands and fingers Keep hands and fingers
clear during operation. clear during operation.
Disconnect power supply Disconnect power supply
and compressed air before and compressed air before

RH
RH
inspection, adjustment, inspection, adjustment,
servicing or maintenance. servicing or maintenance.

ON APPLICATOR
ON APPLICATOR

ATTENTION ATTENTION
Crush hazard Crush hazard
Moving parts below. Moving parts below.
Keep hands and fingers Keep hands and fingers
clear during operation. clear during operation.
Disconnect power supply Disconnect power supply
and compressed air before and compressed air before
inspection, adjustment, inspection, adjustment,

Picture 8 Safety labels kit

servicing or maintenance. servicing or maintenance.

ON BENCH TOP
ON BENCH TOP

FL4050 FL4050

ATTENTION ATTENTION
Crush hazard Crush hazard
Moving parts below. Moving parts below.

different!
different!
Keep hands and fingers Keep hands and fingers
clear during operation. clear during operation.
Disconnect power supply Disconnect power supply

Web path diversi!

Web path diversi!
and compressed air before and compressed air before
inspection, adjustment, inspection, adjustment,
servicing or maintenance. servicing or maintenance.

ON BENCH TOP
ON BENCH TOP
The kit includes all the die cut safety labels that must be applied to the machine.

Vanno usati tutti gli adesivi sulla FL4050. Sulla

Vanno usati tutti gli adesivi sulla FL4050. Sulla

On the FL4050 all labels must be used. On the

On the FL4050 all labels must be used. On the

See manual for label type and position. Web path

See manual for label type and position. Web path

Vedere il manuale per tipo e posizione dell’adesivo.

Vedere il manuale per tipo e posizione dell’adesivo.

AE4050-LD avanzerà l’adesivo indicato dalla freccia.

AE4050-LD avanzerà l’adesivo indicato dalla freccia.

AE4050-LD the label, indicated by the arrow, is extra.

AE4050-LD the label, indicated by the arrow, is extra.

English | Version 1.0 | FL4050 | 47

 3.10.3. Tracking labels
Several identification labels are provided on the various components for tracking purposes.
The labels (60 x 30 mm) have a bar code necessary for handling the pre-assemblies within the
warehouse and during production.

Product description
0000.0000
Lot ID - 000000

XX000000

Picture 9 Tracking label

3.10.4. Identification and certification name plates

The overall unit is supplied with an identification or with an identification and the CE (eventually
the EAC) certification name plate.
If the equipment is considered as partly completed machinery (to be integrated into a second
partly completed machinery or manufacturing system) an identification name plate will be
provided, along with declaration of incorporation.

Weber Marking Systems GmbH Model: XXXXXXXXXXXXX

Maarweg 33
D-53619 Rheinbreitbach
Tel.: +49(0)2224/77080 S/N: 000XXXXX
www.webermarking.de
Equipment: XXXXXXXX
Date: M/YEAR
Power rating: 00-000VAC - 000W MAX

Picture 10 Identification name plate

If the equipment is considered as a machine, an identification and certification name plate will be
provided, along with the declaration of conformity.

Weber Marking Systems GmbH Model: XXXXXXXXXXXXX

Maarweg 33
D-53619 Rheinbreitbach
Tel.: +49(0)2224/77080 S/N: 000XXXXX
www.webermarking.de
Equipment: XXXXXXXX
Date: M/YEAR
Power rating: 00-000VAC - 000W MAX

Picture 11 Identification and certification name plate

48 | FL4050 | Version 1.0 | English

Page intentionally left blank
 CAPITOLO
CHAPTER 41
4. TECHNICAL SPECIFICATIONS
TECHNICAL
INFORMAZIONI
SPECIFICATIONS
GENERALI
Page intentionally left blank
 4.1. FL4050 general features

Picture 12 FL4050 semi-automatic labeling bench

The FL4050 is a semi-automatic Print & Apply labeling bench for self-adhesive flag labels,
normally used on cables or eyeglass temples. Variable data is sent to the Zebra ZE500
print engine, built into the system, which accurately prints the data onto the label, which
is then applied on the product with an accuracy of +/- 1mm.
The electric applicator allows accurate control of speed, acceleration and stroke position
during label application.

Configuration in
Picture 13 From left: the electric applicator with a clamp tamb pad for flag label application, the picture: FL4050
the LCD display control panel and the low label sensor right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 53

 The applicator is supplied with a clamp tamp pad that applies the flag label while folding
it on a cylindrical object or similar with a small diameter. It is possible to purchase
additional different sized clamps to meet any labeling requirement.
The stack lights provide an overview of the machine status. Refer to subparagraph 6.1.5
for a complete description.
The machine is equipped with a low label sensor that detects when the label roll is running
low. The low label warning is visually displayed by the yellow element of the stack lights.
The sensor can be calibrated according to customer needs to minimize downtime.
The system is entirely managed by the 20 x 2-character backlit LCD display control panel
with a user-friendly proprietary software interface. The LCD display control panel is easy to
use. Five buttons manage the menu navigation and start and stop the machining process.
The panel has three management levels (operator, supervisor and service) and is splash
resistant. The LCD display control panel is connected to the machine via an M12 connector.
Refer to subparagraph 6.1.4 for a complete description.

The FL4050 labeling bench has four wheels to easily position the system anywhere.
The main features of the FL4050 semi-automatic labeling bench are:
• Rugged and corrosion-resistant construction in anodized aluminum
and stainless steel
• compact size
• Rewinding mechanism controlled by a step-by-step motor and tension
arm
• low force (< 50 N) on moving parts to ensure operator safety
• splash proof control panel with a 2x20 character LCD display
• Ethernet and USB ports for diagnostics, remote control, firmware
update and configuration
• stack lights
• low label sensor
• thermal transfer print engine, with 16MB SDRAM and 64MB flash
memory, supports user-defined fonts and graphics, including custom
logos. All standard linear and 2D barcodes are supported
• universal power supply 90-264 VAC, with controlled print engine
shutdown

54 | FL4050 | Version 1.0 | English

 4.2. Technical specifications
Table 11 FL4050 specification overview

FL4050
Typical application On static products
Label application method Contact
Labelable product type On cylindrical or similar products with small
diameters
Nominal stroke n.a.
Applicator stroke type Fixed (set by the manufacturer)
Tamp pad type Clamp
Minimum label size n.a.
(W x H)
Maximum label size n.a.
(W x H)
Minimum gap between labels 3 mm
Label sensor Gap sensor, photocell
Max reel external diameter 300 mm
Core diameter Standard (with reel retention system): 76 mm (3”)
Positioning accuracy +/- 1 mm typical
Rewinder motor Microprocessor driven stepper motor. Enables
constant tension on the liner
Rewinding capacity Ø up to 250 mm
Maximum dispensing speed see the specifications of the print engine
on the relative manual included
Application rate 1 Up to 6 cycles/min
Control panel 2 x 20-character backlit LCD display
Control buttons [START], [STOP], [ENTER], [] and []
buttons for navigation
Environment temperature 5 – 35 °C
Environmental conditions 20 - 90 % relative humidity with no condensation
Protection class IP 2X
Operator Interface LCD control display with 20 x 2 lines and 5 buttons
Standard connectors M12 connector for the LCD display
M12 connector for the low label sensor
M12 connector for the product sensor 1
M12 connector for the product sensor 2
M12 connector for the stack lights
DB9 connector for the applicator
DB15 connector for the print engine
DB25 connector for the interface
USB connector
Ethernet connector
1
depends on several factors, such as the speed of the operator, the product and the label
to be applied

English | Version 1.0 | FL4050 | 55

 4.3. Technical data
Table 12 Power supply and absorption

Model Power supply Power consumption

FL4050 580W maximum
90-263 VAC, 48-63 Hz
(including the print engine)

Table 13 Compressed air for applicators (supplied by the customer)

Compressed air quality in accordance with ISO 8573-1.

Compressed air specifications

Flow 200 Nl/min
(0.3 - 3 l/per application cycle)
Pressure da 4 a 6 bar
Maximum number of particles Class 6 ≤ 5mg/m3
per m3 (particle diameter)
Dew point Class 4 +3°C
Oil content Class 5 25 mg/m3

4.4. Options and accessories

Table 14 FL4050 options and accessories

Option/accessory Description
Clamp tamp pad Available in different sizes depending on label size.

56 | FL4050 | Version 1.0 | English

 4.5. Size and weight
4.5.1. FL4050 semi-automatic labeling bench
H1
H

L W

Picture 14 FL4050 size and weight

Table 15 FL4050 size and weight

Model Overall dimensions Weight

L W H/H
1

FL4050 semi-automatic 1025 590 870/1080 90 kg

labeling bench

NOTE:
Machine size and weight are approximate

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 57

 4.6. Operating environment requirements
The room housing the equipment must be a low-vibration, indoor location, protected from
rain, hail, snow, fog, suspended dust, and flammable particles. It must not be a classified
environment. The equipment should not be placed in an area with direct sunlight or near
heat radiators, and should not be used near electrostatic or magnetic fields.

4.7. Environmental working conditions

The equipment is designed to operate in environmental conditions with the following
characteristics:
• Operating temperature: 5 - 35 °C
• Operating humidity (no condensation): 20 - 90 % RH

4.8. Noise
The noise emission of the machine was measured according to the UNI EN ISO 11202:2010
standard at a distance of 1 m from the machine and at a height of 150 cm above the
ground.
• < 72 dB (A)
• < 80 dB (C)

4.9. Altitude
The equipment does not have any particular operating problems related to altitude.

4.10. Electromagnetic compatibility

The equipment complies with the electromagnetic compatibility (EMC) standard (EN
61000).

4.11. Lighting
The room where the equipment is housed must be illuminated so that the control panel
and work areas can be easily identified. In case of scheduled maintenance or servicing the
lighting must allow the required operations to be carried out safely.
• Minimum required illumination: LUX 400

The user is responsible for providing adequate lighting in accordance with current
regulations.
The machine is not equipped with integrated lighting. If the room lighting is less than
prescribed by CEI EN 60 204-1, the technician must be provided with an additional portable
lamp.

58 | FL4050 | Version 1.0 | English

Page intentionally left blank
 CAPITOLO
CHAPTER 51
5. PACKAGING AND TRANSPORTATION
PACKAGING
INFORMAZIONI
AND TRANSPORTATION
GENERALI
Page intentionally left blank
 5.1. Introduction to transportation and installation CAUTION

Read the instructions carefully when installing the machine to avoid risks to third parties
and those involved in the installation.
The equipment may only be installed by technicians properly trained and instructed by
WEBER MARKING SYSTEMS ITALIA or one of its partners. Damage resulting from improper
installation, without the necessary setup, is not covered by warranty.

5.2. Packaging
The equipment and the base of the box are strapped to the pallet. The machine is secured
with packaging film. Included in the box, consisting of the base, the side panels and the
lid, the options and the accessory kit. Once the box has been sealed, it is strapped again to
secure the machine during transportation.

Picture 15 Packaging

Carefully store the packing material for possible future use.

5.3. Delivery inspection

The unit, the accessories, and the options have been inspected prior to shipment and are
in excellent condition. If the received goods are damaged, immediately report them to the
shipper and record them on the delivery note. Please contact WEBER MARKING SYSTEMS
ITALIA or your dealer immediately (refer to subparagraph 1.1.1).
Upon arrival of the goods check:
• the condition of the goods (e.g. absence of dents, signs of humidity)
• the integrity of the supply
• that the numbers of the packages coincide with the accompanying
documentation

These inspections should be conducted visually, with the shipper present, and with the
highest degree of care because damage to materials due to falls is not always immediately
visible. To facilitate these operations, various labels are provided on the packaging of the
products. For more information, refer to subparagraph 5.3.1.
Complaints for damages due to shipping, transportation, unloading, unpacking cannot be
addressed to WEBER MARKING SYSTEMS ITALIA.

English | Version 1.0 | FL4050 | 63

 5.3.1. Identification labels
Each package has at least two different labels to easily recognize the contents:
• product identification label - a label that identifies the product with
the part number [1], product description [2], serial number [3], order
number and date [4]
• Picking list label - a label that identifies the contents of the order
through an internal management number [1] linked to the order
number of the customer [5], the part number [2], the quantity of the
part number ordered [3], the product description [4] and the shipping
address [6]

1 2 3

3 4
5
4
6

Picture 16 On the left, the product identification label, and on the right, the picking list label

Each box has both labels. In case any optional extras are included, the main box will have
the identification label of the base unit and all the labels with the picking list. Inside the
box, each product will be bagged or boxed and will have its own product identification
label.
The range of scenarios is wide, therefore, this is a general guideline to comprehend the
different types of labels during the inspection of the delivery of goods.

64 | FL4050 | Version 1.0 | English

 5.4. Unloading and handling CAUTION

All unloading and handling operations must be carried out in accordance with current
safety regulations and with visual warnings. Lifting and handling operations must be
carried out by specialized personnel trained in this type of maneuver.
PAY SPECIAL ATTENTION TO THE TRANSPORTATION AND INSTALLATION PHASE!
When handling, there is a potential crushing and impact hazard, which can cause the
goods to slip or fall if the operations are not carried out properly. Use personal protective NOTICE
equipment, such as safety shoes and gloves, during unloading and handling operations.
Transport the
No person should be near the suspended load and/or within the range of the lifting system to the
system during handling operations. installation site
in its original
packaging. Do not
5.4.1. General handling procedures open the packaging
until you reach the
When unloading and handling the goods, an electric elevator or forklift truck, suitable for operating area of
the size and weight of the package(s), must be used. Settle the goods by moving the lifting the machine.
system with brief movements until optimal stability is reached. Finally, lift slowly and
handle with the utmost caution, avoiding oscillations.
Transport the labeler to the installation site (within 10 feet/3 meters).

Picture 17 Unloading and handling goods with an electric elevator

NOTE:
WEBER MARKING SYSTEMS ITALIA disclaims all liability caused by improper handling
of the unit

English | Version 1.0 | FL4050 | 65

 CAUTION
5.5. Unpacking
5.5.1. Tools and PPE required for unpacking
The following list includes the tools and personal protective equipment needed when
unpacking the equipment.
• Scissors to cut strappings
• Multipurpose cutter
NOTICE • Safety glasses
Transport the • Gloves
system to the • Safety shoes
installation site
in its original 5.5.2. Opening the packages
packaging. Do not
open the packaging Before opening the box, make sure it is near the installation site (within 10 feet/3 meters).
until you reach the
When unpacking, be extremely careful when cutting the straps. The strappings are very
operating area of
tight. Use personal protective equipment, such as safety shoes, gloves and glasses when
the machine.
unpacking., when cut, they can snap back, causing serious injury.
Use personal protective equipment, such as safety shoes, gloves and glasses, when
unpacking.
Use scissors to cut the outer strapping. Do not use other tools such as multipurpose
cutters, etc.

Picture 18 Opening the box - Step 1

Configuration
in the picture:
AE4050-LD right-
hand version with
rollers for 300 mm
reels.

66 | FL4050 | Version 1.0 | English

Remove the cover of the cardboard box and then the side panels. Inside the box, two
smaller boxes, one with the power supply cable and the rubber guiding rings and one
containing the stack lights.

Picture 19 Opening the box - Step 2

Configuration
in the picture:
AE4050-LD right-
hand version with
rollers for 300 mm
reels.

English | Version 1.0 | FL4050 | 67

 CAUTION Use an all-purpose cutter to remove the packaging film. Use scissors to cut the straps that
secure the machine to the base of the cardboard box.
Be extremely careful when cutting the straps. Use personal protective equipment,
such as safety shoes, gloves and glasses when unpacking.

Picture 20 Opening the box - Step 3

Configuration
in the picture:
AE4050-LD right-
hand version with
rollers for 300 mm
reels.

68 | FL4050 | Version 1.0 | English

Use an electric elevator to move the machine away from the base. The machine should be CAUTION
lifted from underneath, being careful not to hit the electric applicator.
Alternatively, the machine can be lifted by four people equipped with personal protective
equipment such as safety shoes and gloves.

Picture 21 Opening the box - Step 4

Carefully store the packing material for possible future use.

Configuration
in the picture:
AE4050-LD right-
hand version with
rollers for 300 mm
reels.

English | Version 1.0 | FL4050 | 69

 5.6. What's included in the package
5.6.1. FL4050 labeling bench
The following list describes the contents of the FL4050 labeling bench package.

Picture 22 FL4050 labeling bench

Table 16 FL4050 package contents

Quantity Description
1 Main unit strapped to the pallet
1 FL4050 accessory kit
1 Signal tower
1 User manual and CE declaration of conformity
1 Third-party documentation

Table 17 FL4050 accessory kit

Quantity Description
2 Power supply cables with UK and EU plugs (optional for USA)
1 Rubber guide rings

Configuration in
the picture: FL4050
right-hand version
with rollers for 300
mm reels.

70 | FL4050 | Version 1.0 | English

Page intentionally left blank
 CAPITOLO
CHAPTER 61
6. UNIT DESCRIPTION AND OPTIONS
UNIT DESCRIPTION
INFORMAZIONI
ANDGENERALI
OPTIONS
Page intentionally left blank
 6.1. FL4050 main parts CAUTION

The picture illustrates the main parts of the FL4050 labeling bench.

1 2 3 4 5 6 4 7 8 Please read this

user manual
9 carefully.

10

11

12

13

14

15

16

17

20

Picture 23 FL4050 main parts - Front view

1. LCD display
2. Jig (model varies depending on label size)
3. Clamp tamp pad (size varies depending on label size)
4. Label application push button
5. Air assist
6. Zebra ZE500 print engine
7. Low label sensor
8. Paper guide roller
9. Signal tower
10. Product reading scanner
11. Motorized rewinder, Ø 190 mm for reels with core Ø 40 or 76 mm
12. Rewinder dancer roller
13. Rewinder counter flange
14. Mechanical unwinder, Ø 300 mm for reels with core Ø 40 or 76 mm
15. Unwinder dancer roller
16. Unwinder counter flange
17. Applicator
18. Electronics housing
19. Filter regulator with gauge
20. Pedals for label application
21. Junction box

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 75

 20 17 6 6 2 4

11

14

15

21 18 19

Picture 24 FL4050 main parts - Rear panel sectional view

1. LCD display
2. Jig (model varies depending on label size)
3. Clamp tamp pad (size varies depending on label size)
4. Label application push button
5. Air assist
6. Zebra ZE500 print engine
7. Low label sensor
8. Paper guide roller
9. Signal tower
10. Product reading scanner
11. Motorized rewinder, Ø 190 mm for reels with core Ø 40 or 76 mm
12. Rewinder dancer roller
13. Rewinder counter flange
14. Mechanical unwinder, Ø 300 mm for reels with core Ø 40 or 76 mm
15. Unwinder dancer roller
16. Unwinder counter flange
17. Applicator
18. Electronics housing
19. Filter regulator with gauge
20. Pedals for label application
21. Junction box

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

76 | FL4050 | Version 1.0 | English

 6.1.1. Electric applicator
The picture illustrates the main parts of the FL4050 labeling bench applicator.

2 8

10

Picture 25 Main parts of the electric applicator - Left side view

1. Compressed air line inlet 8 mm hose

2. Applicator connection cable
3. 1/8-8 90° fitting
4. Applicator support bracket
5. Air assist 4 mm hose
6. Clamp tamp pad (varies depending on label size)
7. Applicator stroke
8. Bumpers
9. Applicator protection cover
10. Applicator cap

English | Version 1.0 | FL4050 | 77

 6.1.2. Clamp tamp pad
The figure illustrates the main parts of the applicator clamp tamp pad for the FL4050
labeling bench.

2
2

3
7

Picture 26 Main parts of clamp tamp pad of the electric applicator

1. Label application sponge

2. Clamp
3. Ball joint
4. Square tube connection
5. Cylinder
6. End-of-stroke sensor
7. Bracket for cylinders

78 | FL4050 | Version 1.0 | English

 6.1.3. FL4050 labeling bench jig

1 2 3

Picture 27 FL4050 labeling bench jig

1. Protection plate
2. Label passage
3. Stand with guide for product positioning

English | Version 1.0 | FL4050 | 79

 6.1.4. LCD display control panel

1 2 3 4 5 6 7 8 9

Picture 28 LCD display control panel

1. Run LED - LED turns green when the machine is ready to label
2. [START] - Labeler start button. Pressing the button activates labeling
mode and any pending error messages are acknowledged
3. Backlit LCD display with 20 characters x 2 lines
4. [] - left arrow button. Allows to scroll through the various functions
(calibration, recalling and navigating the menu), to change parameters
and to set the label dispensing speed when the labeler is in operation
mode
5. [ENTER] - the button is used to recall the menu, to modify and confirm
a parameter. Moreover, if pressed during the normal operation of the
labeler, it dispenses a label
6. [] - right arrow button. Allows to scroll through the various functions
(calibration, recalling and navigating the menu), to change parameters
and to set the label dispensing speed when the labeler is in operation
mode
7. [STOP] - the button stops labelling mode. Once pressed, the labeler
switches to STAND-BY mode.
8. Stop LED - LED turns red when the machine is stopped
9. Mounting bracket

If all LEDs are off, the labeler is in IDLE mode. Press [START] to switch to READY status.

80 | FL4050 | Version 1.0 | English

 6.1.5. Stack lights
When the machine is in IDLE mode, after the machine is powered on (ON/OFF switch), the
red element of the stack lights is lit. During IDLE mode, the motors are disabled, the air tank
is empty and the solenoid valves are de-energized. By pressing the [START] button on the
display, the machine performs a ”homing” cycle and fills the air tank. At the end of the cycle, the
motors remain in torque and the machine switches to READY status and waits for the signal to
start the cycle. The green element of the indicator light is on.
By pressing the [STOP] button on the display, the applicator rod moves to the paper loading
position and the motors remain in torque even if the machine does not accept the signal to
start the cycle. The machine enters STAND-BY mode and the red element of the indicator light
lights up. By pressing the [STOP] button again, the machine enters IDLE mode. Instead, by
pressing the [START] button on the display, the machine enters READY status.
The red element of the indicator light turns on when the machine detects an error. The
machine enters ALARM status. It is necessary to solve the cause of the error (refer to chapter
11) and re-arm the machine by pressing the [START] button on the display.
If the low label sensor detects that the label reel is about to run out, the yellow element of the
stack lights will light up. In this case, the green element also remains lit. If the label reel runs
out, the yellow element remains lit and the red element will light up because a printer and/or
rewinder timeout error will be automatically generated.

Picture 29 3-element stack lights

1. Red element - alarm indicator

2. Yellow element - low label sensor warning
3. Green element - normal operation
4. Signal tower body
5. Support bracket
6. Cable

NOTE:
The stack lights may vary depending on availability

English | Version 1.0 | FL4050 | 81

 6.1.6. Low label sensor
The low label sensor sends a signal to the machine when the label roll reaches a preset limit.
The sensor is connected via a 1-meter cable with an M12 connector to the “Low label sensor”
connector on the connector panel (Picture 35, point 10).
Please refer to paragraph 8.12 for operation and subparagraph 8.5.2 for maintenance.

1 2 3 4 5 6

Picture 30 Low label sensor

1. Transmitter
2. Receiver
3. Green LED
4. Yellow LED
5. Bracket
6. Multi-turn potentiometer

82 | FL4050 | Version 1.0 | English

 6.1.7. Counter flanges, support rings and guide rings
The counter flanges lock the label reels and scrap core in place for improved accuracy
during both, product label application and scrap collection. Counter flanges can be used
with 76mm label reels.
Four rubber label guide rings aid in keeping the liner in place without slipping on both
paper guide rollers.
Please refer to paragraph 8.6 for the use of counter flanges, paragraph 8.4.3 for the use
of support rings and paragraph 8.4.4 for the use of rubber guide rings.

3 1

Picture 31 Unwinder and rewinder counter flanges

1. PVC support ring

2. 190 mm counter flange for rewinder with PVC support ring
3. 300 mm counter flange for unwinder with PVC support ring
4. Rubber guide ring

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 83

 CAUTION 6.1.8. Zebra ZE500 print engine
The Zebra ZE500 print engine is an industrial-grade direct thermal and thermal transfer
label printer, capable of handling high-resolution user-defined fonts and graphics. The
engine supports all standard linear and 2D barcodes. Please refer to the corresponding
Please refer to the user manual for more information.
print engine user
manual included in
the shipment.

1 2 3 4 5 6 7 8 9

Picture 32 Zebra ZE500 print engine - External front view

1. Display
2. Lower guide post
3. Peel roller latch
4. Protection hatch
5. Peel roller assembly (hidden when closed)
6. Power switch
7. Control panel (for more information please refer to subparagraph 8.5.2)
8. Platen roller
9. Peel bar
10. Upper guide post
11. Ribbon supply spindle
12. Pinch roller assembly
13. Media guide
14. Ribbon take-up spindle
15. Printhead-release latch
16. Printhead assembly (shown open)
17. Parallel port
18. USB 2.0 port
19. Wired Ethernet port
Images of the 20. RS-232 serial port
print engine ZE500 21. Applicator interface connector
courtesy of Zebra 22. A/C power supply connector
Technologies

84 | FL4050 | Version 1.0 | English

 2 10 11 12 13 3 5 14 15 8 9 16

Picture 33 Zebra ZE500 print engine - Interior view of the components

1. Display
2. Lower guide post
3. Peel roller latch
4. Protection hatch
5. Peel roller assembly (hidden when closed)
6. Power switch
7. Control panel (for more information please refer to subparagraph 8.5.2)
8. Platen roller
9. Peel bar
10. Upper guide post
11. Ribbon supply spindle
12. Pinch roller assembly
13. Media guide
14. Ribbon take-up spindle
15. Printhead-release latch
16. Printhead assembly (shown open)
17. Parallel port
18. USB 2.0 port
19. Wired Ethernet port
20. RS-232 serial port
21. Applicator interface connector
22. A/C power supply connector

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 85

 17 18 19 20 21 22

Picture 34 Zebra ZE500 print engine - Rear view

1. Display
2. Lower guide post
3. Peel roller latch
4. Protection hatch
5. Peel roller assembly (hidden when closed)
6. Power switch
7. Control panel (for more information please refer to subparagraph 9.7.8)
8. Platen roller
9. Peel bar
10. Upper guide post
11. Ribbon supply spindle
12. Pinch roller assembly
13. Media guide
14. Ribbon take-up spindle
15. Printhead-release latch
16. Printhead assembly (shown open)
17. Parallel port
18. USB 2.0 port
19. Wired Ethernet port
20. RS-232 serial port
21. Applicator interface connector
22. A/C power supply connector

Images of the
print engine ZE500
courtesy of Zebra
Technologies

86 | FL4050 | Version 1.0 | English

 6.2. The connector panel
6.2.1. FL4050 connector panel
The connector panel of the FL4050 labeling bench has several connectors, in addition to
the ON/OFF switch, the mains socket with a V-Lock fuse holder, and the power socket for
the print engine. The screen printing on the connector panel simplifies the connection of
the various components.

2
8

3
10

11

12
4

5
13

Picture 35 FL4050 connector panel

1. Printer - Print engine connector

2. Applicator - Applicator connector
3. Interface - I/O signals connector
4. USB type B connector
5. ON/OFF switch
6. Printer power supply - IEC 60320 power supply socket for the print
engine
7. Alarm lamp - 8-pin M12 stack lights connector
8. Product sensor P - 5-pin M12 product sensor connector
9. Product sensor S - 5-pin M12 connector (not used)
10. Low label sensor - 5-pin M12 low label sensor connector
11. Ethernet - RJ45 network connector for setup, remote control or service
12. Display - M12 display connector
13. IEC 60320 mains socket with V-Lock fuse holder

English | Version 1.0 | FL4050 | 87

 6.2.2. Junction box
A junction box, located on the back of the machine, manages the I/O connections
necessary to control the buttons and scanners located on the upper side of the machine. A
DB-25 connector connects the junction box to the connector panel of the semi-automatic
labelling bench. For further information, refer to the wiring diagrams in chapter 12.

1
4

Picture 36 Junction box

1. DB-25 male connector for I/O signals

2. Cable gland for the wiring of the trigger buttons
3. Cable gland for the wiring of the right-hand product scanner
4. Cable gland for the wiring of the left-hand product scanner
5. Unused cable gland

88 | FL4050 | Version 1.0 | English

 6.3. Signal description
6.3.1. Print engine signals
Signals on the “X23 Printer” DB-15 type, male connector (Picture 35, point 1). For more
information, please refer to the AP4080 Programming and Interfacing Guide.

15

Picture 37 Print engine connector

Table 18 Description of the signals on the print engine connector

Pin Name Type Description

X23:1-8 GROUND Return path for power and common
reference for signals
X23:2 +5V auxiliary power Routed to pin 6 of the DB-25 interface
connector via a jumper
X23:3 START PRINT OUTPUT Open collector line, activated (short
circuited to ground) by the applicator to
issue a label request to the print engine
X23:4 FEED OUTPUT Open collector line, normally inactive.
If barcode/RFID reading is enabled via
service parameter 028, this line outputs
an internally generated REPRINT signal,
alternative to the one normally available on
pin 6.
X23:5 PAUSE OUTPUT Open collector line, normally inactive
(reserved for future use)
X23:6 REPRINT OUTPUT Open-collector line that replicates the state
of the equivalent signal coming from pin 21
of the DB-25 interface connector
X23:7 +24/28V printer INPUT This line is detected by the hardware to
power input recognize whether the print module is ON
or OFF. As a result, it turns the applicator
power ON or OFF (less than 20 mA required)
X23:9 RIBBON INPUT Line normally held low (0V) by the print
module. It is raised (+5V) when the transfer
ribbon is almost finished
X23:10 ERROR INPUT Normally high line (+5V). It is lowered (0V) by
the print module when an error condition
occurs
X23:11 PRINT INPUT Normally high line (+5V). It is lowered (0V)
by the print module during the printing
operation or when loading a label
X23:12-13 Do not connect
X23:14 DATA READY INPUT Normally high line (+5V). It is lowered (0V)
by the print module when data is available
to print a label
X23:15 TEST OUTPUT Pin connected to the internal +24V supply
through a 330-ohm resistor. Disconnected
during normal operation

English | Version 1.0 | FL4050 | 89

 6.3.2. Applicator signals
Signals on the “X8 Applicator” DB-9 type, female connector (Picture 35, point 2). For more
information, please refer to the AP4080 Programming and Interfacing Guide.

Picture 38 Applicator connector

Table 19 Description of the signals on the applicator connector

Pin Name Type Description

X8:1-6 +24V power Short-circuit protected (max 1.5A)
X8:2-7 +48V optional
power
X8:3 INTERNAL BIDIRECTIONAL Half-duplex serial line used to
NETWORK communicate between the various slave
modules of the machine and the main
controller
X8:4-5-9 GROUND Return path for power and common
reference for signals
X8:8 TRIGGER1 OUTPUT Repeats the signal of TRIGGER1 and
Primary Product Sensor inputs

90 | FL4050 | Version 1.0 | English

 6.3.3. Interface signals WARNING

Signals on the “X9 Interface” DB-25 type, female connector (Picture 35, point 3). For more
information, please refer to the AP4080 Programming and Interfacing Guide.
When using
inductive loads, a
suitable protection
1
diode must be
25 used to protect the
internal drivers
from dangerous
Picture 39 Interface connector
overvoltages

Table 20 Description of the signals on the interface connector

Pin Name Type Description

X9:1 +24V auxiliary Over current protected (max 300 mA)
power
X9:2-4 SYNC OUTPUT Gives an end-of-cycle command or a cycle-
in-progress command, depending on the
selected machine configuration (can also be
used to give a read command to a barcode
scanner)
X9:3-16 HOME OUTPUT It is active when the tamp pad is in home
position (fully retracted) and the machine is
READY, or in a STAND-BY condition (it is not
active in the initial IDLE condition). Its use as
the only source signal to implement a safety
interlock function is NOT recommended
X9:5-19 PRINT OUTPUT Signal that reproduces the end of printing
signal available on pin 11 of the DB-15
printer connector and is active during the
printing phase
X9:6 +5V auxiliary power Comes from pin 2 of the DB-15 printer
connector via a jumper
X9:7-20 Opto-isolated OUTPUT These outputs can be used to:
auxiliary outputs • activate the read command of a
OO1 barcode scanner
• report a barcode scanner reading error
• restart the master (or upstream) device
in a tandem configuration
• replicate the READY relay output on
a master (or upstream) device of a
tandem configuration
• enable the conveyor movement signal,
controlled by bit 1 of service parameter
#315
X9:8-9-22 READY/ALARM relay The N.O. contact (pin 9-22) is closed when
contacts the machine is ready or performing an
application cycle. The N.C. contact (pin 8-22)
is closed when the machine is not in an
operating condition (may be error, STAND-
BY or OFF).

English | Version 1.0 | FL4050 | 91

 Pin Name Type Description
X9:10-14 LABEL-CONVEYOR OUTPUT Its function is determined by bit 0 of service
parameter 005. In LABEL mode it is active
when there is a label on the plate (detected
by the vacuum). In CONVEYOR mode it can
be used as the product movement enable
signal or to activate the read command of a
barcode scanner
X9:11-24 Low paper/low OUTPUT Activated when the sensor located near the
ribbon WARNING unwinder has detected that the label reel
is almost finished. If pin 9 of the printer
connector is active, it indicates that the
ribbon is almost finished
X9:12-15 DATA OUTPUT The signal that reproduces the data ready
signal available on pin 14 of the DB-15
connector of the print engine and it is
active when the printer is ready to print the
received data
X9:13 GROUND Return path for auxiliary power supply
X9:17 TRIGGER1 INPUT It can be used as a programmable trigger
signal. It is in parallel with the signal coming
from the M12 connector of the primary
product sensor
X9:19 TRIGGER3 INPUT It can be used as a programmable
trigger signal or, depending on machine
configuration, as a remote control to stop or
restart the machine
X9:21 REPRINT-SPARE INPUT If the machine is equipped with the old
black cable, it is connected to the equivalent
signal available on pin 6 of the print module
connector and can be used to send a
reprint command from an external device.
With the new white cable, this signal can
be configured for different purposes
(activation of the reprint cycle, reading from
a barcode scanner, etc.)
X9:23 TRIGGER2 INPUT It can be used as a programmable trigger
signal. It is in parallel with the signal from
the M12 connector of the secondary
product sensor
X9:25 Common input signal connection

NOTE:
To avoid potential interference, use a shielded cable to connect external
devices to the INTERFACE connector and provide good electrical contact
of the cable shield to the metal body of the connector

92 | FL4050 | Version 1.0 | English

 6.3.4. Stack lights signals
Signals on the “X6 Alarm lamp” M12, female connector (Picture 35, point 7). For more
information, please refer to the AP4080 Programming and Interfacing Guide.

3
8
1

4
7

6
Picture 40 Stack lights connector

Table 21 Description of the signals on the stack lights connector

Pin Name Type Description

X6:1 +24V Red element power supply (alarm indicator)
X6:2 +24V Yellow element power supply (low label
sensor or end ribbon warning)
X6:3 +24V Green element power supply (normal
operation)
X6:4-5-6-7 Not connected
X6:8 GROUND

English | Version 1.0 | FL4050 | 93

 6.3.5. Primary product sensor signals
Signals on the “X2 Product sensor P” 5-pin M12, female connector (Picture 35, point 8). For
more information, please refer to the AP4080 Programming and Interfacing Guide.

2
3
5
1
4
Picture 41 Primary product sensor connector

Table 22 Description of the signals on the primary product sensor connector

Pin Name Type Description

X2:1 +24V Power supply
X2:2 This line can be connected via internal
jumpers to GROUND or +24V, or it can be
used as an alternative input signal
X2:3 GROUND
X2:4 Sensor signal INPUT It can be configured via software for NPN or
PNP sensors (must be the same type as the
secondary product sensor)
X2:5 Connected to pin 5 of the secondary
product sensor connector

94 | FL4050 | Version 1.0 | English

 6.3.6. Secondary product sensor signals
Signals on the “X22 Product sensor S” 5-pin M12, female connector (Picture 35, point 9). For
more information, please refer to the AP4080 Programming and Interfacing Guide.

2
3
5
1
4
Picture 42 Secondary product sensor connector

Table 23 Description of the signals on the secondary product sensor connector

Pin Name Type Description

X22:1 +24V Power supply
X22:2 This line can be connected via internal
jumpers to GROUND or +24V, or it can be
used as an alternative input signal
X22:3 GROUND
X22:4 Sensor signal INPUT It can be configured via software for NPN or
PNP sensors (must be the same type as the
primary product sensor)
X22:5 Connected to pin 5 of the primary product
sensor connector

English | Version 1.0 | FL4050 | 95

 6.3.7. Low level sensor signals
Signals on the “X3 Low label sensor” 5-pin M12, female connector (Picture 35, point 10). For
more information, please refer to the AP4080 Programming and Interfacing Guide.

2
3
5
1
4
Picture 43 Low label sensor connector

Table 24 Description of the signals on the low label sensor connector

Pin Name Type Description

X3:1 +24V Power supply
X3:2 This line can be connected via internal
jumpers to GROUND or to +24V
X3:3 GROUND
X3:4 Sensor signal INPUT An internal jumper allows the selection of
NPN (default) or PNP
X3:5 Do not connect

96 | FL4050 | Version 1.0 | English

 6.3.8. Display signals
Signals on the “X10 Display” 5-pin M12, female connector (Picture 35, point 12). For more
information, please refer to the AP4080 Programming and Interfacing Guide.

2
3
5
1
4
Picture 44 Display connector

Table 25 Description of the signals on the display connector

Pin Name Type Description

X10:1 +24V Power supply
X10:2 Do not connect
X10:3 GROUND
X10:4 Do not connect
X10:5 NETWORK BIDIRECTIONAL Half-duplex serial line used to communicate
between the various slave modules of the
machine and the main controller

English | Version 1.0 | FL4050 | 97

 6.3.9. WIZ107SR-TTL Ethernet interface
The system implements a standard 100BASE-T wired Ethernet connection (Picture 35, step
11), with an RJ45 jack. With the default configuration, the Ethernet connection obtains its
IP address and other LAN parameters through a DHCP server. Ethernet parameters can be
changed through the control panel or using the ApController remote control software. The
Ethernet interface communicates through TCP port 9100, so the user must make sure that
a device, like a proxy server in the LAN does not filter it.
It is possible to select whether the power supply for the Ethernet connector is provided
(normally closed) or not from jumper JP16 on the Smd CPU board. Also, connecting pin 1-2
will give a +5V power supply, while connecting pin 2-3 (default position), the power supply
will give +3.3V.
Please refer to the AP4080 Programming and Interfacing Guide for more information.
applicator
interface

ethernet
Picture 45 Ethernet connector

6.3.10. USB interface

encoder

display

The system implements a standard Type B USB jack (Picture 35, item 4) and can be used to
lamp

USB

connect a PC for setup, diagnostics, and remote control.

The device is USB 2.0 (Full Speed) compliant and supports bidirectional mass transfers
with data packages up to 64 bytes. It emulates on the USB interface the classic behavior of
a simple RS232 device that communicates with ASCII text characters. Unless a dedicated
applicator

application program with its specific driver is installed on the PC, it is necessary to install at
least one USB driver per virtual serial port and use a simple terminal emulation program.
All modern operating systems include the driver.
The USB device does not draw power from the cable, so it requires the machine to be
turned on regularly to operate.
ethernet
Please refer to the AP4080 Programming and Interfacing Guide for more information.
encoder

display

USB

Picture 46 USB connector

98 | FL4050 | Version 1.0 | English

 6.3.11. Signals for interface from the connector on
the junction box
The signals on the DB-25 male connector (Picture 36, item 1) on the junction box. Refer to
the AP4080 Programming and Interfacing Manual for more information.

Picture 47 Connector for interface on junction box

Table 26 Description of the signals on the connector for the interface on the junction box

Pin Name Type Description

X9:1 +24V auxiliary Over current protected (max 300 mA)
power
X9:2-4 SYNC OUTPUT Gives an end-of-cycle command or a cycle-
in-progress command, depending on the
selected machine configuration (can also be
used to give a read command to a barcode
scanner)
X9:3-16 HOME OUTPUT It is active when the tamp pad is in home
position (fully retracted) and the machine is
READY, or in a STAND-BY condition (it is not
active in the initial IDLE condition). Its use as
the only source signal to implement a safety
interlock function is NOT recommended
X9:5-19 PRINT OUTPUT Signal that reproduces the end of printing
signal available on pin 11 of the DB-15
printer connector and is active during the
printing phase
X9:6 +5V auxiliary power Comes from pin 2 of the DB-15 printer
connector via a jumper
X9:7-20 Opto-isolated OUTPUT These outputs can be used to:
auxiliary outputs • activate the read command of a
OO1 barcode scanner
• report a barcode scanner reading error
• restart the master (or upstream) device
in a tandem configuration
• replicate the READY relay output on
a master (or upstream) device of a
tandem configuration
• enable the conveyor movement signal,
controlled by bit 1 of service parameter
#315
X9:8-9-22 READY/ALARM relay The N.O. contact (pin 9-22) is closed when
contacts the machine is ready or performing an
application cycle. The N.C. contact (pin 8-22)
is closed when the machine is not in an
operating condition (may be error, STAND-
BY or OFF).

English | Version 1.0 | FL4050 | 99

 Pin Name Type Description
X9:10-14 LABEL-CONVEYOR OUTPUT Its function is determined by bit 0 of service
parameter 005. In LABEL mode it is active
when there is a label on the plate (detected
by the vacuum). In CONVEYOR mode it can
be used as the product movement enable
signal or to activate the read command of a
barcode scanner
X9:11-24 Low paper/low OUTPUT Activated when the sensor located near the
ribbon WARNING unwinder has detected that the label reel
is almost finished. If pin 9 of the printer
connector is active, it indicates that the
ribbon is almost finished
X9:12-15 DATA OUTPUT The signal that reproduces the data ready
signal available on pin 14 of the DB-15
connector of the print engine and it is
active when the printer is ready to print the
received data
X9:13 GROUND Return path for auxiliary power supply
X9:17 TRIGGER1 INPUT It can be used as a programmable trigger
signal. It is in parallel with the signal coming
from the M12 connector of the primary
product sensor
X9:19 TRIGGER3 INPUT It can be used as a programmable
trigger signal or, depending on machine
configuration, as a remote control to stop or
restart the machine
X9:21 REPRINT-SPARE INPUT If the machine is equipped with the old
black cable, it is connected to the equivalent
signal available on pin 6 of the print module
connector and can be used to send a
reprint command from an external device.
With the new white cable, this signal can
be configured for different purposes
(activation of the reprint cycle, reading from
a barcode scanner, etc.)
X9:23 TRIGGER2 INPUT It can be used as a programmable trigger
signal. It is in parallel with the signal from
the M12 connector of the secondary
product sensor
X9:25 Common input signal connection

NOTE:
To avoid potential interference, use a shielded cable to connect external
devices to the INTERFACE connector and provide good electrical contact
of the cable shield to the metal body of the connector

100 | FL4050 | Version 1.0 | English

 6.4. Buttons and switches
The following picture illustrates the location of the label application buttons and the ON/
OFF switch on the FL4050 semi-automatic labeling bench.

1 2

Picture 48 Application buttons and ON/OFF switch on the FL4050

1. ON/OFF switch
2. Label application buttons

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 101

 WARNING
6.5. Electrical components
6.5.1. Description of the FL4050 labeling bench
electronics housing
The electronics of the FL4050 semi-automatic labeling bench is divided into two parts: one
integrated directly into the cover and one mounted on the housing plate.
The removal of the
protective covers The picture illustrates the electronics housing cover with the integrated components. For
must be carried out clarity purposes, not all wiring is shown.
only by authorized
personnel for
maintenance and
service.
Before removing
the electronics
housing cover, turn
the main power
switch off and
lock it to prevent
unintentional
4
reactivation. If
possible, disconnect
the equipment from
the power supply.

Picture 49 Description of the electronics housing cover

1. Main board (CPU)

2. 65W 24V 80-264Vac 2xMOPP Class II switching power supply unit
3. WIZ107SR-TTL Ethernet module
4. Main board and Picsmd board connection cable for rewinder motor
(Picture 50, point 8)
Configuration in 5. Grounding. Must be connected to DC 2A stepper motor for the
the picture: FL4050 rewinder (Picture 50, point 7)
right-hand version
with rollers for
300 mm reels.

102 | FL4050 | Version 1.0 | English

The following picture illustrates the part of the components mounted on the electronics
housing plate. For clarity purposes, not all wiring is shown.

Picture 50 Description of the electronics housing on the plate

6. Rewinder dancer roller photocell

7. DC 2A stepper motor for the rewinder
8. Picsmd board for the rewinder motor

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 103

 6.5.2. Description of the electrical applicator
electronics housing
The picture illustrates the electronic components of the electrical applicator.

Picture 51 Description of the electric applicator electronics

1. DC 2A stepper motor
2. Electric applicator board
3. 3-valve applicator board

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

104 | FL4050 | Version 1.0 | English

 6.6. Description of the FL4050
labeling bench modules
6.6.1. CPU board
The main board (CPU) handles the logics of the system and all peripherals. Jumpers on
the board are highlighted in light red. For more information, please refer to the AP4080
Programming and Interfacing Guide.

9
4

8 5

Picture 52 Main board (CPU)

1. LD1: Factory diagnostic LED

2. J14: Ethernet module connector
3. J10: auxiliary device connector (example: motorized unwinder)
4. J9: rewinder connector
5. J11: power supply connector
6. J15: optional encoder input
7. J16: optional analog input (example: it can be used to connect a
distance measuring device)
8. J17: optional opto isolated output
9. J13: microcontroller programming connector

English | Version 1.0 | FL4050 | 105

 6.6.2. 65W 24V 80-264Vac 2xMOPP Class II
switching power supply
There are two 65W 24V power supplies connected in pairs that power the unit.

FS1 AC FUSE HS100

T2A/250V

3
18
2 CN2
1 1
CN1 2
6
3
4

LED
HS1 SVR1

Picture 53 65W 24V power supply

1. CN1: AC input connector

2. CN2: DC output connector

106 | FL4050 | Version 1.0 | English

 6.6.3. WIZ750SR Ethernet module
The WIZ750SR Ethernet module provides a 100BASE-T LAN connection, through an RJ45 jack.

1 2 3

6 4

Picture 54 Wiz750SR Ethernet module

1. ISP mode connector

2. Power supply LED
3. Status LED:
• blue: PHY connection status
• green: TCP connection status
4. Main board (CPU) connector
5. GPIO expansion / App boot connector
6. RJ45 connector with transformer

English | Version 1.0 | FL4050 | 107

 6.6.4. Rewinder motor Picsmd board
The Picsmd board manages the rewinder motor. Highlighted in light red the board jumper.
For more information, please refer to the AP4080 Programming and Interfacing Guide.

1 J1

2 J7

J5 J4 J3 J2

3 4 5 6

Picture 55 Rewinder motor Picsmd board

1. J1: rewinder motor connector

2. J7: not available
3. J5: Smd CPU board connection connector on J4 connector
4. J4: analogue input connector for the rewinder dancer roller photocell
connection
5. J3: digital input connector (not connected)
6. J2: programming connection (not connected)

108 | FL4050 | Version 1.0 | English

 6.7. Description of the electric applicator modules
6.7.1. 5-valve applicator board
The electric applicator board manages the solenoid valves (refer to subparagraph 6.8.5)
and measures the pressures used by the unit. The jumpers on the board are highlighted in
light red. For more information, please refer to the AP4080 Programming and Interfacing
Guide.

5 6 7

4 J9 8
PS1

PS2
3

9
J7

J5
10
J2

2
J8

11
J1

JP11

1
JP10
JP4
JP1

JP7
J6

12

13

Picture 56 5-valve applicator board

1. J1: contacts for the programming connection

2. J8: rod release analog input/output connector
3. J7: PhoenixNet and power supply contacts
4. PS1: pressure sensor
5. J9: additional proximity sensor contacts
6. J3: proximity sensor contacts
7. J4: home sensor contacts
8. PS2: vacuum sensor
9. J5: additional I/O contacts
10. J2: additional input contacts
11. Diagnostic LED
12. J6: valve output contacts
13. Solenoid valve assembly (for details, subparagraph 6.8.5)

English | Version 1.0 | FL4050 | 109

 6.7.2. Electric applicator board
The electric applicator board controls the motor of the applicator that allows the tamp
pad to move up and down. Highlighted in light red the jumpers on the board. For more
information, please refer to the AP4080 Programming and Interfacing Guide.

1 J1

2 J7

J5 J4 J3 J2

3 4 5 6

Picture 57 Electric applicator board

1. J1: applicator motor connection contacts

2. J7: not available
3. J5: PhoenixNet and power supply contacts
4. J4: analog input contacts (not used)
5. J3: home sensor contacts (proximity)
6. J2: programming connection contacts

110 | FL4050 | Version 1.0 | English

 6.8. Pneumatics description WARNING

6.8.1. Description of the pneumatic components

of the FL4050 labeling bench
The following picture illustrates the pneumatic components of the FL4050 semi-automatic
labeling bench.
The removal of the
protective covers
must be carried out
only by authorized
personnel for
maintenance and
17
1 service.
Before removing
2 the electronics
housing cover, turn
the main power
16 switch off and
lock it to prevent
unintentional
3 reactivation. If
possible, disconnect
4
the equipment from
the power supply.

15
14
6

13 7

8
12

11

10 9

Picture 58 Description of the pneumatics of the FL4050 labeling bench - Side view

1. Clamp tamp pad

2. Air assist
3. 8 mm polyurethane hose for the general air supply (outside the applicator)
4. 6 mm polyurethane hose for the general air supply inside the applicator
5. 8 mm polyurethane hose that supplies air to the tamp pad (performs
vacuum)
6. Quick exhaust valve
7. Air tank
8. 6 mm polyurethane hose that supplies air from the main supply to the
solenoid valve unit
9. Solenoid valve assembly (refer to subparagraph 6.8.5)
10. 8 mm polyurethane air main supply hose (by customer)
11. 6 mm polyurethane tube for clamp opening
12. Filter regulator with gauge (refer to subparagraph 6.8.4)
13. 6 mm polyurethane hose for the measurement of the air supply pressure
14. 6 mm polyurethane hose for vacuum generation
15. Vacuum generator Configuration in
16. 4 mm polyurethane hose for the air assist air supply the picture: FL4050
17. Flow regulator for the adjustment of the air assist right-hand version
18. 6 mm polyurethane tube for clamp closing with rollers for
19. 6mm polyurethane hose for the measurement of the vacuum 300 mm reels.

English | Version 1.0 | FL4050 | 111

 16

14

12

16

18

11

10

Picture 59 Description of the pneumatics of the FL4050 labeling bench - Rear view

1. Clamp tamp pad

2. Air assist
3. 8 mm polyurethane hose for the general air supply (outside the applicator)
4. 6 mm polyurethane hose for the general air supply inside the applicator
5. 8 mm polyurethane hose that supplies air to the tamp pad (performs
vacuum)
6. Quick exhaust valve
7. Air tank
8. 6 mm polyurethane hose that supplies air from the main supply to the
solenoid valve unit
9. Solenoid valve assembly (refer to subparagraph 6.8.5)
10. 8 mm polyurethane air main supply hose (by customer)
11. 6 mm polyurethane tube for clamp opening
12. Filter regulator with gauge (refer to subparagraph 6.8.4)
13. 6 mm polyurethane hose for the measurement of the air supply pressure
14. 6 mm polyurethane hose for vacuum generation
15. Vacuum generator
16. 4 mm polyurethane hose for the air assist air supply
17. Flow regulator for the adjustment of the air assist
18. 6 mm polyurethane tube for clamp closing
19. 6mm polyurethane hose for the measurement of the vacuum

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

112 | FL4050 | Version 1.0 | English

2

19

5
15
11
18

10

Picture 60 Description of the pneumatics of the FL4050 labeling bench - Front view

1. Clamp tamp pad

2. Air assist
3. 8 mm polyurethane hose for the general air supply (outside the applicator)
4. 6 mm polyurethane hose for the general air supply inside the applicator
5. 8 mm polyurethane hose that supplies air to the tamp pad (performs
vacuum)
6. Quick exhaust valve
7. Air tank
8. 6 mm polyurethane hose that supplies air from the main supply to the
solenoid valve unit
9. Solenoid valve assembly (refer to subparagraph 6.8.5)
10. 8 mm polyurethane air main supply hose (by customer)
11. 6 mm polyurethane tube for clamp opening
12. Filter regulator with gauge (refer to subparagraph 6.8.4)
13. 6 mm polyurethane hose for the measurement of the air supply pressure
14. 6 mm polyurethane hose for vacuum generation
15. Vacuum generator
16. 4 mm polyurethane hose for the air assist air supply
17. Flow regulator for the adjustment of the air assist
18. 6 mm polyurethane tube for clamp closing
19. 6mm polyurethane hose for the measurement of the vacuum

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 113

 6.8.2. Clamp tamp pad pneumatic connections
Below are the pneumatic components of the applicator clamp tamp pad for the FL4050
labeling bench.

2
2

3
2

4
12

7
5

7
10

11 10

11

Picture 61 Main parts of clamp tamp pad of the electric applicator

1. Sponge for label application

2. Clamp
3. 4 mm tube that conveys air to generate the vacuum (on both clamps)
4. Spherical joint
5. Square tube connection
6. Cylinder
7. Flow regulator for closing the corresponding clamp
8. 4 mm tube that conveys the air to open the corresponding clamp
9. 4 mm tube that conveys the air to close the corresponding clamp
10. End-of-stroke sensor
11. Flow regulator for the opening of the corresponding clamp
12. Bracket for cylinders

114 | FL4050 | Version 1.0 | English

 6.8.3. Air assist
The air assist helps the label adhere perfectly to the applicator tamp pad by blowing
compressed air over it once it is peeled off the liner. At this point, the tamp pad is able
to generates a vacuum effect that keeps the label firmly attached to the pad for perfect
application.
The thin tube can be oriented to match the size of the label. The airflow can be adjusted by
opening or closing a screw on the flow regulator. Refer to subparagraph 8.13.4 for more
information.

1 2 3 4 4 4

Picture 62 Descrizione dell’air assist

1. 1/8-4 V flow regulator

2. Fixing ring nut
3. 4” nickel plated tube
4. Airflow microholes

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 115

 6.8.4. Compressed air management unit
The filter regulator [1], mounted on the rear side of the machine, supplies the applicator
with dry compressed air, necessary to:
• generate the vacuum effect that allows the label to adhere to the tamp pad
• blast the label on the product
• supply the air assist that holds the label flat on the tamp pad when it is
fed out of the printer

The 8 mm hose that connects the main air supply line to the machine-mounted filter
regulator should NOT exceed 10 feet in length (3 meters). Comply with the air specifications
indicated in Table 13. For longer lengths, it is necessary to change the pressure regulator
quick connect fitting to one with a higher flow rate and connect a hose with a larger
diameter.
The pressure gauge [2] must be set to a value between 4 and 6 bar. Different pressure
values may adversely affect the system and the quality of label application. For any
corrections, use the air delivery knob [1], turning clockwise to increase or counterclockwise
to decrease the pressure.

8
1
7

Picture 63 Description of the compressed air management unit

1. Air supply to the machine (8 mm hose)

2. Pressure gauge
3. Removable filter cup with metal protection
4. Condensation discharge screw
5. Compressed air supply line inlet (8 mm hose)
6. Sleeve valve
7. Knurled nut
8. Pressure adjustment knob

116 | FL4050 | Version 1.0 | English

 6.8.5. Solenoid valve assembly for the electric
applicator
There are several solenoid valves inside the applicator and they manage air assist, vacuum
and blast.

6
2

Picture 64 Solenoid valve assembly for the electric applicator

1. 22mm, 24 Vdc, 2.5W solenoid for V1 valve

2. 22mm, 24 Vdc, 2.5W solenoid for V2 valve
3. 22mm, 24 Vdc, 2.5W solenoid for V3 valve
4. 22mm, 24 Vdc, 2.5W solenoid for V4 valve
5. 22mm, 24 Vdc, 2.5W solenoid for V5 valve
6. 5 valve group
• V1: vacuum generation
• V2: quick air discharge (blast)
• V3: air management for the air assist
• V4: clamp closure management
• V5: clamp aperture management

English | Version 1.0 | FL4050 | 117

7. INSTALLATION AND SETUPCAPITOLO
CHAPTER 71
INSTALLATION
INFORMAZIONIAND
GENERALI
SETUP
Page intentionally left blank
 7.1. Preparing for installation CAUTION

The labelling machine must be installed by a specialized technician to guarantee correct

and fault-free operation. It is necessary to make some fine adjustments, based on the
conditions of use, that only a technician authorized by WEBER MARKING SYSTEMS ITALIA
is able to carry out, due to the specific knowledge acquired in years of experience. This
manual does not cover all the cases and problems that may occur during the installation
phase, therefore, it is not sufficient to carry out an installation without a final inspection
and testing.
Damage resulting from improper installation without the necessary setup is not
covered by the warranty.

7.1.1. Installation requirements

The installation site must have the following characteristics:
• Indoor, dry and clean installation area
• horizontal flat surface that does not sag and near a power outlet
• low vibration environment
• adequate lighting (minimum 400 Lux)
• no direct sunlight or heat radiation
• environment with no electrostatic or magnetic fields, which can lead to
malfunctions or application problems
• electrical power supply socket in compliance with current regulations,
suitable for the characteristics of the equipment (please refer to the
technical specifications described in paragraph 4.2)
• compressed air supply line, if applicable
• ambient temperature between +5°C and +35°C, with relative humidity
between 20% and 90% (no condensation)

7.1.2. Tools required for installation and maintenance

The following list includes the tools needed when installing the equipment.
• Hexagon socket wrench set
• Screwdriver with different inserts (Philips, Torx, flat, etc.)
• Hook tool for spring traction
• Miscellaneous tools

7.1.3. Installation site

Upon arrival of the equipment, all finishing operations of the environment (basements,
partitions, walls, columns, protective panels, etc.) must have already been completed.
Treatment of the floor with anti-slip products is suggested. The connection points to the
electrical power and compressed air lines must already have been arranged, according to
the technical specifications and current regulations. The connection to the electrical mains
must be available in the vicinity of the operating area of the equipment.
During installation, the machine operator is directly responsible for the safety of the
personnel authorized to unload, unpack, and perform installation-related tasks.

English | Version 1.0 | FL4050 | 121

 CAUTION 7.1.4. Safety area
The area around the equipment from the operator side must guarantee the safety of
personnel involved in normal operations and setting adjustments. The area towards the
machine front must be sufficient for material loading and unloading operations. The
area around the machine rear must guarantee ordinary and extraordinary maintenance
operations. We recommend a distance of at least one meter between the machine and
walls or partitions. The system has been designed to be used by a single operator.

100 cm

100 cm 100 cm
Machine rear Machine front

100 cm
Operator side

Picture 65 Safety area

Loading and unloading operations and ordinary and extraordinary maintenance

activities must be carried out only when the unit is stopped.

122 | FL4050 | Version 1.0 | English

 7.2. Warnings on installation and commissioning
7.2.1. Safety warnings
Hazard due to direct or indirect contact with live parts
DANGER OF DEATH! WARNING
Contact between people and energized components can result in death.
• Interventions on electrical parts must be carried out in a workmanlike
manner by specialized electricians
• The electrical parts of the labelling machine should be checked
regularly
• Fix loose connections and replace damaged cables
• Always keep the electronics housing closed
• Before working on electrical equipment, turn the main power switch
off and lock it to prevent unintentional reactivation. If possible,
disconnect the equipment from the mains

Hazard due to highly flammable material in storage CAUTION

FIRE HAZARD!
Stored films and labels can be easily ignited. Risk of injury from fire and released fumes.
• Keep stored material away from heat sources and open flames

Hazards due to moving parts CAUTION

RISK OF DRAGGING AND CRUSHING!
Drag and crush hazard from pneumatic or motorized components of the unit.
• Do not put hands or other parts of the body in the areas of the
equipment subject to movement
• Wear only tight-fitting, tear-resistant, short-sleeved clothing
• Do not wear ties, bracelets, watches or similar items

First start-up of the labelling machine must be carried out only by trained technical NOTICE
personnel.

English | Version 1.0 | FL4050 | 123

 CAUTION
7.3. Installation of the FL4050
semi-automatic labeling bench
Installation 7.3.1. Foreword
procedures should Consider the following points for proper positioning of the labeling machine.
be carried out
by authorized • Make sure there is always sufficient space for the normal operations
personnel only. of use, adjustments, loading and unloading material and ordinary and
extraordinary maintenance
• A power connection must be available in the vicinity of the operating
site of the equipment
• The floor of the location site of the machine must be solid, horizontal
and well leveled

Complete the steps described in the following subparagraphs to install the machine and
related components. WEBER MARKING SYSTEMS ITALIA recommends that the machine is
installed by properly trained personnel to avoid any problems.
To ensure safety standards, the connection of the machine to the mains must be carried
out in a workmanlike manner, according to the electrical regulations in force.
For the electrical supply of the system, it is necessary to prepare a panel with line sockets
and prepare a switch with magnetothermal and differential protection with a threshold of
30mA upstream of the socket.
We recommend verifying the grounding of the equipment once connections have been
completed.

CAUTION 7.3.2. Lifting and handling the machine

The machine can be lifted using a pallet stacker or, alternatively, by four people wearing
personal protective equipment like safety shoes and gloves. If a pallet stacker is used,
the machine should be lifted from underneath, being careful to avoid hitting the electric
applicator.

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels. Picture 66 Lifting the machine

124 | FL4050 | Version 1.0 | English

The machine is equipped with four swiveling wheels [1 and 2] so it can be moved easily.
Two of them have brakes. Once the machine has been positioned in the chosen labeling
area, make sure to lock the two wheels with the brakes [1] by pressing the lever [3],
indicated in the picture.

1 3 2

Picture 67 Handling the machine

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 125

 CAUTION 7.3.3. Installing reel dragging rings
The reel dragging rings lock the cardboard core of the label reel so when the unwinder
(bottom) or rewinder (top) spindle rotates, the core cannot spin freely. When the machine
is delivered, the dragging rings are mounted to secure the counter flange assembly to the
unwinder and rewinder. It is necessary to disassemble the dragging rings [1], support rings
[2] and counter flanges [3] and reassemble them correctly.
Pay attention when working with the slats of the dragging rings, as they can cause slight
skin injury. It is recommended to wear protective gloves.

Picture 68 Dragging rings and counter flanges

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

126 | FL4050 | Version 1.0 | English

Follow the next steps on both the unwinder (bottom) and the rewinder (top).
Slightly unscrew the galvanized aluminum reel dragging ring setscrew [1] with a size 4 Allen
key, as illustrated, and pull the ring off. Do not completely unscrew the setscrew.

Picture 69 Installation of the reel dragging rings - Step 1

Slide off the black PVC support ring [2] without unscrewing the ring setscrew.

Picture 70 Installation of the reel dragging rings - Step 2

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 127

 Remove the polycarbonate counter flange [3] without unscrewing the setscrew of the black
PVC support ring.

Picture 71 Installation of the reel dragging rings - Step 3

Insert the reel dragging ring [1] into the spindle with the slats facing upwards. This will make
it easier to adjust them later (see subparagraph 8.4.2). Tighten the setscrew (located at the
bottom) with an Allen key size 4.

Picture 72 Installation of the reel dragging rings - Step 4

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

128 | FL4050 | Version 1.0 | English

 7.3.4. Adjusting the gaskets of the reel support rings
and the counter flanges
The reel support rings and counter flanges have a green colored gasket [1] that must
be adjusted when the machine arrives to the customer. For transportation reasons, the
gaskets cannot be adjusted before delivery. This operation is necessary to be able to
lock the reel support rings and the counter flanges when the machine is in operation.
The procedure is very simple: by rotating the reel support ring or counter flange, with the
setscrew facing the flat part of the spindle, the gasket does not come in touch with the
spindle and the reel support ring or counter flange can be removed. By rotating the reel
support ring or counter flange with the setscrew over the rounded part of the spindle, the
gasket locks the ring or counter flange in place.
This procedure must be carried out on both the unwinder (bottom) and the rewinder (top).

1 1

Picture 73 Reel support ring gasket (left) and counter flange (right)

Insert and rotate the black PVC support ring [2] so that the setscrew coincides with the
round part of the spindle [3] of the unwinder or rewinder. Screw in the setscrew with a size
5 Allen key until some resistance is noticed.

Configuration in
the picture: FL4050
right-hand version
with rollers for
Picture 74 Adjustment of support ring gasket and counter flanges - Step 1 300 mm reels.

English | Version 1.0 | FL4050 | 129

 Rotate the reel support ring [2] towards the flat part and make sure that rotation is smooth
without excessive strain. When rotating the ring back towards the round part of the roller,
a certain resistance should be noticed in order to lock it in place.

Picture 75 Adjustment of support ring gasket and counter flanges - Step 2

Insert and rotate the black ring of the polycarbonate counter flange [3] so that the
setscrew coincides with the flat part of the spindle [4] of the unwinder or rewinder. Tighten
the setscrew with a size 5 Allen key until some resistance is noticed.

Picture 76 Adjustment of support ring gasket and counter flanges - Step 3

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

130 | FL4050 | Version 1.0 | English

Rotate the counter flange [4] towards the flat and make sure that rotation is smooth
without excessive strain. When rotating the counter flange towards the round part of the
roller, a certain resistance should be noticed in order to lock it in place.

Picture 77 Adjustment of support ring gasket and counter flanges - Step 4

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 131

 7.3.5. Installing the stack lights
Inside the machine packaging a box containing the wired stack lights and bracket, which
must be mounted on the machine. The stack lights must be mounted on the side of
the machine where the electronics housing is visible on the upper aluminum profile, as
illustrated in the picture.
Slightly screw two M6 hex socket screws in the two N10-M6 hammer nuts, without
tightening.

Picture 78 Installation of the stack lights - Step 1

Insert the hammer nuts into the groove of the aluminum extrusion and tighten the two
screws with a 4” Allen key.

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels. Picture 79 Installation of the stack lights - Step 2

132 | FL4050 | Version 1.0 | English

Insert the M12 connector of the stack lights to the Alarm lamp connector (Picture 35, step
7) on the connector panel and screw it in.

Picture 80 Installation of the stack lights - Step 3

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 133

 7.3.6. Compressed air supply line connection
The machine requires a connection to an existing compressed air supply line (provided by
the customer) in order to operate. Refer to Table 13 for compressed air characteristics.
Connect an 8 mm polyurethane compressed air hose (maximum length 10 feet/3 meters)
to the pressure regulator quick connect fitting (refer to subparagraph 6.8.4) mounted
on the back of the machine to the lower right. The quick-connect fitting is accessible from
the front of the machine. Do not exceed the maximum distance of 10 feet/3 meters from
the compressed air inlet to the pressure regulator, as this could have negative effects on
the system and the quality of the label application and on the proper performance of the
labelling machine. If the machine is located further away from the airline inlet, replace the
quick-connect fitting on the pressure regulator with one having a higher flow rate, so that a
hose with a larger diameter can be connected.
The pressure gauge should be set between 4 and 6 bar. Different pressure values may
adversely affect the system and the quality of label application. For corrections, pull the
pressure adjustment knob upward to disengage the anti-torsion guard. Turn clockwise to
increase or counterclockwise to decrease pressure. Once the correct pressure is set, push
the pressure adjustment knob down.

Configuration in
the picture: FL4050
right-hand version Picture 81 Compressed air connection
with rollers for
300 mm reels.

134 | FL4050 | Version 1.0 | English

 7.3.7. Connection to the electrical network WARNING

To ensure safety standards, the connection of the machine to the mains must be carried
out in a workmanlike manner and in accordance with current electrical regulations.
The supply voltage is:
• 110-230 Volt 50-60 Hz Before connecting
the power supply,
For other voltages, please contact WEBER MARKING SYSTEMS ITALIA Technical Service make sure that the
Department. circuit breaker with
magnetothermal
The FL4050 semi-automatic labeling bench is supplied with different power supply cables
and differential
to meet various operational requirements. Should it be necessary to use cables with
protection is closed.
different plugs, the cable must have a diameter of 7.5 mm and a maximum length of 2
meters. The grounding
system must
comply with the
Schuko plug (Europe) British plug American plug regulations in force
in the country
where the machine
is installed.

Picture 82 Power supply cables supplied

Select the correct power supply cable, according to the country of installation, and
connect the female plug to the power supply connector (Figure 34, item 13) located on the
connector panel of the machine, as illustrated. Make sure the system is always connected
to an interference-free AC power source, and that no high-voltage equipment, which may
cause line interference, is connected to the same power line.
Always disconnect the power supply before moving the machine.

Configuration in
the picture: FL4050
right-hand version
Picture 83 Connection to the electrical network with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 135

 7.3.8. PC connection for data management
During the labeling phase, the operator approaches the scanner with a data source that
is read by the device. The information is forwarded to the management system of the
company and the data that will be printed on the label are loaded on the print engine.
It is necessary to connect both USB connectors [1] on the scanner cables to the PC [2] if the
machine is used alternately by two operators.
In case only one user operates the machine, connect the USB connector of the selected
scanner to the PC [2]. If both scanners are connected, the cycle indicating the number of
operators set will automatically exclude the second device.

Picture 84 PC connection to the FL4050 semi-automatic labeling bench

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

136 | FL4050 | Version 1.0 | English

Page intentionally left blank
8. MACHINE OPERATION CAPITOLO
CHAPTER 81
INFORMAZIONI
MACHINE OPERATION
GENERALI
Page intentionally left blank
 8.1. Preliminary information CAUTION

8.1.1. Foreword
WEBER MARKING SYSTEMS ITALIA controls and performs a series of tests on all machines
before delivery to guarantee high quality standards and calibrate the machines according Please read the user
to the type of processing required. manual carefully.

Follow the indications described in this chapter to use the machine correctly and chapter 9
for maintenance. WEBER MARKING SYSTEMS ITALIA declines any responsibility for non- CAUTION
compliance with the regulations in force and for any kind of negligence in the use of the
equipment.
Before switching on, check that the compressed air connections (see subparagraph
7.3.6) and the power supply connection (see subparagraph 7.3.7) have been carried out The person in
correctly. charge of the
equipment and
This section contains all the safety precautions that must be followed for the proper use
the operators in
of the machine. In addition, there are also procedures that must be carried out during the
charge of its use
initial start-up and others during the normal use of the machine.
must comply with
It is therefore recommended that this section be read very carefully. all regulations and
legal requirements
It is forbidden: regarding accident
• to remove any safety guards prevention and
• to disable safety devices (if any) safety at the
• to modify or add devices to the electrical system without prior written workplace.
authorization or the technical intervention of the manufacturer The person in
• to use the equipment for purposes other than those described in this charge of the
user manual equipment must
• to allow unauthorized personnel the use the equipment be familiar with
• to clean or perform maintenance while the equipment is running the hazards within
• to sit or stand on the labeling bench the workplace
and be aware of
In case of equipment with a pneumatic system, it is strictly forbidden to disassemble the the emergency
pneumatic connections while the machine is connected to the mains. Hoses may contain procedures.
high-pressure air. The work area must
While using the machine or as soon as the production cycle is over, be careful with the high be illuminated in
temperature of some components, such as motors, bearings and hoses. Always wait for accordance with
temperatures to drop below 40-50°C. all applicable
standards during
operation,
maintenance and
8.1.2. Environmental working conditions
service operations.
It is recommended to use the machine in working environments with temperatures
between 5 and 35 °C and with 20 - 90 % relative humidity with no condensation. Values
other than those mentioned above may affect the correct application of the labels and the
proper functioning of the system.

8.1.3. Checkup prior to system startup

Before turning on the machine make sure that:
• all of the steps for proper installation described in chapter 7 have
been completed (first startup after installation)
• the electrical and pneumatic connections have been carried out
correctly (first startup after installation)
• the compressed air pressure gauge indicates a value between 4 and 6
bar (as specified in Table 13)
• there are no obstructions that could block the operation of the
unwinder, rewinder and applicator
• safety requirements are met
• the operator has been properly trained
• the operator always remains in the positions indicated in paragraph
8.2 and its subsections, according to the type of operation carried out

English | Version 1.0 | FL4050 | 141

 8.2. Position of the operator
8.2.1. Foreword
No particular health hazards are associated with the machine during installation, normal
use and maintenance. Refer to paragraph 3.9 for the residual risks of the FL4050 semi-
automatic labeling bench.

8.2.2. Setup
The preferable position of the operator during setup is illustrated below.

Picture 85 Position of the operator during setup operations

8.2.3. Loading and unloading label reels

The position of the operator when loading and unloading label reels is illustrated below.

Picture 86 Position of the operator when loading and unloading label reels
Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

142 | FL4050 | Version 1.0 | English

 8.2.4. Labeling with two operators
The following illustrates the position of the operators when labeling with two operators.

Picture 87 Position of the operators during the labelling phase

8.2.5. Labeling with one operator

The position of the operator during the labelling phase with a single operator is illustrated
below. The operator can stand in front of the machine or at the back of the machine,
depending on the configuration selected.

Configuration in
the picture: FL4050
Picture 88 Operator position during the labeling phase right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 143

 8.3. Startup of the machine
8.3.1. Turning on the machine
Once the system is plugged into the power outlet, turn on the machine by pressing the
button [1] on the connector panel, as indicated in the picture. The button lights up when
the machine is powered.
Once the FL4050 semi-automatic labeling bench is turned on, the machine status is IDLE
and the red indicator light is ON. Since the label roll is not mounted during the first startup,
the yellow indicator light will be ON. In IDLE status, the motors are disabled, the air tank is
empty, and the solenoid valves are de-energized.

Picture 89 Turning on the machine

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

144 | FL4050 | Version 1.0 | English

 8.4. Loading the reel CAUTION

8.4.1. Introduction
The system must work only with tested flag labels. Labels must be on a liner, manufactured
using compliant materials and sized for the type of application required. The glue must be
evenly distributed.
When carrying
out operations as
loading label reels
8.4.2. Adjusting the slats or installing the
printing ribbon,
Both the unwinder and rewinder can be equipped with 3” (76 mm) nominal internal
do not wear
diameter cores. A dragging ring [1], located at the end of the spindle of the unwinder and
rings, watches,
rewinder, keeps the core blocked in place so that it does not rotate freely, compromising
necklaces, hanging
the correct application of the labels on the product and the proper functioning of the
identification
labeling bench.
badges, etc.
Each dragging ring has two slats [2]. Each slat has two slotted holes so their position on the
ring can be precisely adjusted to compensate the tolerance of the core diameter, ensuring
a perfect grip.

2 2 1

Picture 90 Adjusting the dragging ring slats - Step 1 Configuration in

the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 145

 To adjust the slats, insert the scrap collection core [3] on the rewinder spindle and on the
dragging ring. Push the core all the way on without forcing it. Mount the label reel on the
unwinder.

Picture 91 Adjusting the dragging ring slats - Step 2

As a general rule, the core [3], highlighted in gray, should fit the dragging ring so that the
slats [1] exert a slight pressure. If adjusted correctly, the slats will slightly mark the inside
of the core in correspondence. If the core fits loosely, it will rotate freely. If the slats only
touch the core without locking it, the cardboard of the core will create residue that could
compromise the correct application of the label. Be careful not to force the core with too
much pressure on the dragging ring.

NO YES NO

Configuration in
the picture: FL4050 Picture 92 Adjusting the dragging ring slats - Step 3
right-hand version
with rollers for
300 mm reels.

146 | FL4050 | Version 1.0 | English

To adjust the position of the slats [2], slightly loosen the two screws [4] that fasten the slats
to the dragging ring [1] with an Allen key size 3. Adjust the position of both slats and tighten
the screws.

2 4 2 4 1

Picture 93 Adjusting the dragging ring slats - Step 4

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 147

 8.4.3. Loading the core and label reel
Before mounting the core on the rewinder and the label reel on the unwinder, mount the
support rings that provide stability to both the core and the label reel during machine
operation.
Insert the support ring [1] on both the rewinder and the unwinder, as illustrated in the
picture, with the setscrew [2] toward the flat part of the spindle [3].

1 2 3

Picture 94 Mounting the core and label reel - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

148 | FL4050 | Version 1.0 | English

Place the core [4] next to the support ring [1] of the rewinder. Slide the ring on the spindle
until a 1 cm gap between the core (highlighted in gray in the second figure) and the support
ring allows the user to grasp the core easily when replacing it.

1 4

4 1

TOP VIEW 10 mm

Picture 95 Mounting the core and label reel - Step 2

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 149

 Block the support ring [1] by rotating it so that the setscrew [2] coincides with the round
part [5] of the spindle.

5 1 2

Picture 96 Mounting the core and label reel - Step 3

Insert the core [4] until it is against the flange [7] of the rewinder. A slight resistance should
be noticed as the core slips onto the dragging ring [6].

4 1 6 7
Configuration in
the picture: FL4050
right-hand version Picture 97 Mounting the core and label reel - Step 4
with rollers for
300 mm reels.

150 | FL4050 | Version 1.0 | English

Place the label reel [8] next to the support ring [1] of the unwinder. Slide the ring on the
spindle until a 1 cm gap between the label reel (highlighted in gray in the second figure)
and the support ring allows the user to grasp the reel easily when replacing it.

8 1

1 8

10 mm

TOP VIEW

Picture 98 Mounting the core and label reel - Step 5

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 151

 Block the support ring [1] by rotating it so that the setscrew [2] coincides with the round
part [5] of the spindle.

5 1 2

Picture 99 Mounting the core and label reel - Step 6

Insert the label reel [8] until it is against the flange [9] of the unwinder. A slight resistance
should be noticed as the reel slips onto the dragging ring [6].

8 1 6 9
Configuration in
the picture: FL4050
right-hand version Picture 100 Mounting the core and label reel - Step 7
with rollers for
300 mm reels.

152 | FL4050 | Version 1.0 | English

 8.4.4. Adjusting the rubber guide rings
Fit the rubber guide rings [10] on both the paper guide rollers [11], as illustrated. Do not
lose the ring spring. The side with the spring must face the flange.

11 11 10 10

Picture 101 Adjusting the rubber guide rings - Step 1

Set up the web path [12] as described in subparagraph 8.4.5. Fit the second pair of rubber
guide rings [13] with the spring facing outward the paper guide rollers [11].

Configuration in
the picture: FL4050
11 13 13 11 12 right-hand version
with rollers for
Picture 102 Adjusting the rubber guide rings - Step 2 300 mm reels.

English | Version 1.0 | FL4050 | 153

 The rubber guide rings [10 and 13] must be positioned about 2 mm from the label stock,
highlighted in gray.

2 mm 2 mm

10 13 11

Picture 103 Adjusting the rubber guide rings - Step 3

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

154 | FL4050 | Version 1.0 | English

 8.4.5. Labeling bench web path
Once the slats on the drive rings have been adjusted and the core and label reel have been
positioned, peel the first 3 feet/1 meter of labels off the liner. The label reel should be
oriented so the material passes through the printhead with the labels facing upward.
Carry out steps [1, 2, 3 and 4] of the web path, as illustrated in the picture (start from
the label reel). Make sure that the inner edge of the label liner is kept straight all the way
through the printer.
Carry out the web path in the Zebra ZE500 print engine. Please refer to subparagraph
8.5.5 and the manufacturer’s manual provided with the documentation inside the
packaging.
Proceed with steps [5 and 6] only after the media has been fed through the print engine.
Attach the flap of the liner to the core mounted on the rewinder with a label. Turn the
rewinder spindle until the liner is tensioned. Normally it is necessary to turn the spindle 2
or 3 times to tension the liner correctly.

4 3 6 5

1 2

Picture 104 Labeling bench web path

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 155

 CAUTION
8.5. Zebra ZE500 print engine
8.5.1. Introduction
The Zebra ZE500 print engine is an industrial-grade direct thermal and thermal transfer
label printer. It can manage user-defined fonts and high-resolution graphics. The module
supports all standard linear and 2D barcodes. For more information, please refer to the
When carrying relevant user manual.
out operations as
loading label reels
or installing the
printing ribbon,
do not wear
rings, watches,
necklaces, hanging
identification
badges, etc.

Picture 105 Zebra ZE500 print engine

NOTE:
The print engine is mounted on the labeling bench rotated 180 degrees
compared to the picture above. Images are indicative only and should be
used only as a guide

Images of the
print engine ZE500
courtesy of Zebra
Technologies

156 | FL4050 | Version 1.0 | English

 8.5.2. Print engine control panel
All print engine controls and indicators are located on the control panel of the module. The
power switch is located above the control panel. For more information and configuration of
settings, please refer to the manufacturer’s manual included with the delivery.

7 8 9 10 11 12 13 14 15

1 2 3 4 5 6

Picture 106 Print engine control panel

1. Display - shows the operating status of the print engine and allows the
user to navigate the menus
2. [] button - switches to the previous parameter in the menu
3. Minus button [-] - allows to change parameter values. Common uses
are decreasing a value, scrolling through entries or changing the
position of the cursor when entering the print engine password
4. [] button - switches to the next parameter in the menu
5. [CANCEL] button - cancel jobs that are being printed when the print
engine is paused
6. [CALIBRATE] button - calibrates the print engine for media length and
sensor values
7. Plus button [+] - allows to change parameter values. Common uses are
increasing a value, scrolling through entries or changing the position of
the cursor when entering the print engine password
8. Power indicator light - the light turns ON when the print engine is ON
9. [SETUP] button - allows access and exit configuration mode
10. Pause indicator light - The light turns ON when the print engine is
paused
11. Print engine ON/OFF switch
12. Status indicator light
• Off - normal operation
• On - a print engine error has occurred. For more information check
the display
13. [PAUSE] button - allows to suspend or resume the print engine
operation
14. Data indicator light
• Off - normal operation. No data is being received or processed
• On - the print engine is processing data or is printing. No data is
being received
• Blinking - the print engine is receiving data or sending
status information to the host computer
15. [FEED] button - when pressed a blank label is fed into the print engine

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 157

 CAUTION 8.5.3. Thermal transfer labels
or direct thermal printing?
Thermal transfer printing uses a print head that heats a carbon graphic ribbon which
transfers the color onto the plain paper label.
Wait for the print
engine printhead to Direct thermal printing, on the other hand, requires the use of chemical paper labels. The
cool down before chemical paper reacts to the heat generated by the printhead and causes a color change to
performing any create the printed image.
operation with the
protective panel Choosing which printing method is preferable depends on the use of the label. If the
open. product to be labeled has to be exposed outdoors, under direct sunlight, in harsh
environmental conditions such as humidity, or comes into contact with chemicals, it is
advisable to use thermal transfer. Direct thermal printing is a good solution when the
life cycle of the labels is short (ex.: shipping labels), as chemical paper tends to fade and
discolor when subjected to heat sources and over time.
It should also be considered that thermal transfer printing can be used on a wide range
of materials and the printhead lifespan is longer because the ribbon works also as a pad
between the printhead and the label. This implies, however, proper training to replace the
ribbon when it runs out. Thermal transfer printing requires more maintenance than direct
thermal printing. Direct thermal printing, on the other hand, is easier to handle even if it
has a higher wear of the printhead because of the direct contact with the label that rubs
during the transfer.

8.5.4. Loading the ribbon

The ribbon is used exclusively with thermal transfer labels. If you are printing direct
thermal labels, do not load the ribbon into the print engine.
Use a ribbon wider than the label roll to protect the printhead from wear. Refer to the
manufacturer’s manual included in the delivery for ribbon specifications.
Open the print engine protection hatch.

Picture 107 Opening the print engine

NOTE:
The print engine is mounted on the labeling bench rotated 180 degrees
compared to the picture above. Images are indicative only and should be
Images of the
used only as a guide
print engine ZE500
courtesy of Zebra
Technologies

158 | FL4050 | Version 1.0 | English

Rotate the printhead release latch to the open position.

Picture 108 Loading the ribbon - Step 1

Position the ribbon with the loose end unwinding in the direction shown.

Picture 109 Loading the ribbon - Step 2

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 159

 Insert the ribbon spool onto the ribbon supply spindle and push it all the way in.

Picture 110 Loading the ribbon - Step 3

Insert an empty ribbon spool onto the ribbon take-up spindle and push it all the way in.

Images of the Picture 111 Loading the ribbon - Step 4

print engine ZE500
courtesy of Zebra
Technologies

160 | FL4050 | Version 1.0 | English

Thread the ribbon under the lower ribbon guide roller (1), under the printhead assembly
(2), and then over the upper ribbon guide roller (3).

1 2 3

Picture 112 Loading the ribbon - Step 5

Wind the ribbon around the core on the ribbon take-up spindle.

Picture 113 Loading the ribbon - Step 6

NOTE:
Images of the
The print engine is mounted on the labeling bench rotated 180 degrees
print engine ZE500
compared to the picture above. Images are indicative only and should be
courtesy of Zebra
used only as a guide
Technologies

English | Version 1.0 | FL4050 | 161

 CAUTION 8.5.5. Loading the label reel
Press the release button on the pinch roller assembly. Allow the assembly to pivot upward.

Wait for the print

engine printhead to
cool down before
performing any
operation with the
protective panel
open.

Picture 114 Loading the label reel - Step 1

Slide the media guide all the way out.

Images of the
print engine ZE500
courtesy of Zebra
Technologies Picture 115 Loading the label reel - Step 2

162 | FL4050 | Version 1.0 | English

Thread the media under the upper guide post (1), below the pinch roller assembly (2), and
under the printhead assembly (3).

1 2 3

Picture 116 Loading the label reel - Step 3

Extend approximately 30 inches/75 centimeters of liner past the peel bar. Remove and
discard the labels from the liner on this exposed media.

Images of the
print engine ZE500
courtesy of Zebra
Picture 117 Loading the label reel - Step 4
Technologies

English | Version 1.0 | FL4050 | 163

 Slide in the media guide until it just touches the edge of the liner.

Picture 118 Loading the label reel - Step 5

Press down on the pinch roller assembly until it locks closed.

Images of the Picture 119 Loading the label reel - Step 6

print engine ZE500
courtesy of Zebra
Technologies

164 | FL4050 | Version 1.0 | English

Rotate the printhead-release latch to the closed position.

Picture 120 Loading the label reel - Step 7

Raise the peel roller latch so that the peel roller assembly pivots downward.

Picture 121 Loading the label reel - Step 8

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 165

 Thread the liner around the peel bar, under the platen roller, and through the peel roller
assembly.

Picture 122 Loading the label reel - Step 9

Rotate the peel roller assembly up until it locks into the closed position.

Picture 123 Loading the label reel - Step 10

Images of the
print engine ZE500
courtesy of Zebra
Technologies

166 | FL4050 | Version 1.0 | English

Close the print engine protection hatch.

Picture 124 Closing the print engine

Continue with the web path on the FL4050 labeling bench steps [5 and 6]) as described in
subparagraph 8.4.5.

NOTE:
The print engine is mounted on the labeling bench rotated 180 degrees
compared to the picture above. Images are indicative only and should be
used only as a guide

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 167

 8.6. Using the counter flanges
The counter flanges lock the label reel and waste collection core in place for greater
accuracy during both label application to the product and waste collection. Counter flanges
can be used with 4”/76 mm label rolls.
Fit the counter flange [1] on the rewinder until it is against the core, as illustrated. The
setscrew [2] must be oriented towards the flat part of the spindle [3].

3 2 1

Picture 125 Using the counter flanges - Step 1

Block the counter flange [1] by rotating it so the setscrew [2] coincides with the round part
[4] of the spindle.

Configuration in
the picture: FL4050 1 4 2
right-hand version
with rollers for Picture 126 Using the counter flanges - Step 2
300 mm reels.

168 | FL4050 | Version 1.0 | English

Fit the counter flange [1] on the unwinder until it is against the label reel, as illustrated. The
setscrew [2] must be oriented towards the flat part of the spindle [3].

3 2 1

Picture 127 Using the counter flanges - Step 3

Block the counter flange [1] by rotating it so the setscrew [2] coincides with the round part
[4] of the spindle.

1 4 2

Picture 128 Using the counter flanges - Step 4

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 169

 8.7. Machine start-up
The FL4050 labeling bench is already configured and ready to use. No setup is required.
Once the machine is switched on (see subparagraph 8.3.1), the following screen will
appear on the display:

AE4080.t10 87A3
PRESS <START>

AE4080.t10 is the machine firmware and 87A3 is the machine identification code.
After a few seconds the first line will change to check the machine modules. The machine is
in an IDLE status (motors disabled, air tank empty and solenoid valves de-energized).
Press the [START] button on the display to perform the homing cycle and fill the air tank. The
machine will switch to the READY status (motors are in torque) and the screen will display:

AE4080.t10 C0 00000
ATT.INIZIO CICLO 03

The machine firmware is always visible. C0 appears on the right indicating which cycle is
active. The value 00000 is the progressive number of the counter of labels applied (the
counter reaches 25,599 labels and then automatically resets).
The second line indicates the machine status in that precise moment.

8.7.1. Setting the number of operators

The system is designed to be used either by two operators alternating or by a single
operator. The default configuration is with two operators. If only one operator is using
the machine, the configuration must be changed. Below is an explanatory table with the
different configurations available.

Table 27 Summary of available configurations

Configuration Details
000 Default configuration using two alternating operators
001 Configuration not available. The setup is related to configuration 000
and manages operator number 1
002 Configuration not available. The setup is related to configuration 000
and manages operator number 2
003 Configuration involving the use of a single operator, machine front
004 Configuration involving the use of a single operator, machine rear
005 Open configuration
006 Open configuration
007 Open configuration

170 | FL4050 | Version 1.0 | English

To change configuration, according to the number of available operators, press the [STOP]
button on the control panel with LCD display, shown in the figure in step 5, to switch to
STAND-BY mode.

1 2 3 4 5

Picture 129 Pulsanti sul display LCD

1. [START] button
2. [] button
3. [ENTER] button
4. [] button
5. [STOP] button

The screen displays:

AE4080.t10 C3 00000
STAND-BY

Press the [ENTER] and the [] button simultaneously:

CONFIGURATION 001
SELECT CONFIG: 000

The default configuration is 000 in which two operators are employed.

Press [ENTER] again. The last digit of the parameter flashes. Press the [] button until the
desired configuration is selected. In this example configuration number 003 was selected
(refer to the table on the previous page):

CONFIGURAZIONE 001
SELEZIONA CONF. 003

Press [ENTER] to confirm the selection. The last digit stops flashing. Press [START] to
perform the homing cycle and fill the air tank. The machine switches to the READY status
(motors in torque) and the screen displays:

AE4080.t10 C0 00000
WAIT CYCLE TRIG 03

English | Version 1.0 | FL4050 | 171

 CAUTION
8.8. Processing cycle with two operators
Following are the instructions to use the semi-automatic labeling bench with two operators
and the sequence of an entire label application cycle. Many of the items on the display will
be visible for a very short time. Each subparagraph indicates the task the operator must
carry out.
Do not wear Make sure that the chosen configuration matches the number of operators. Refer to
rings, watches, subparagraph 8.7.1.
necklaces, hanging
identification The machine is ready to receive the cycle request from the first operator:
badges, etc., during
the processing AE4080.t10 C0 00000
cycle. WAIT CYCLE TRIG 03

8.8.1. Machine reservation by the operator

Press the foot pedal [1] or the illuminated trigger button [2] to reserve the labeler. The
button on the reserved side lights up and the scanner activates [3], ready to scan a
barcode. When one side of the machine is reserved, the second side will be disabled until
the end of the cycle.

Configuration in
the picture: FL4050
right-hand version Picture 130 Machine reservation
with rollers for
300 mm reels.

172 | FL4050 | Version 1.0 | English

 8.8.2. Scanning the product
The scanner [3] must detect the barcode that identifies the product to retrieve the
information that will be printed on the label.

Picture 131 Barcode scanner

While waiting for the barcode to be scanned, the screen will display:

AE4080.t10 C0 00000
WAITING LABEL

Place the source with the barcode [4] close to the enabled scanner [3].

4 3

Configuration in
the picture: FL4050
right-hand version
with rollers for
Picture 132 Barcode scanning 300 mm reels.

English | Version 1.0 | FL4050 | 173

 ATTENZIONE The WAITING LABEL status will remain until the management system sends the data to
be printed to the print engine. Once the bar code that identifies the product to be labeled
has been read, the information is sent directly to the print engine. While the label is being
printed, the LCD screen displays:

AE4080.t10 C0 00000
Pay attention LABEL PRINTING
during the
extension of the
tamp pad. The
The tamp pad vacuum system remains on hold until the printed label is ejected from the
extension area
print engine:
must be clear of any
object or body part
that could obstruct
AE4080.t10 C0 00000
the movement of WAITING VACUUM 006
the mechanism.

The tamp pad draws the label [5] and the applicator arm rises level with the notch [6] on
the jig support:

AE4080.t10 C0 00000
PLATE EXTENSION

5 6

Picture 133 Clamp tamp pad extension

The machine will wait for the application trigger to be sent by the operator either by
pressing the foot pedal or the light button:

AE4080.t10 C0 00000
WAIT CYCLE TRIG 01

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

174 | FL4050 | Version 1.0 | English

 8.8.3. Product labeling
Place the product to be labeled [7] on the jig as shown.

Picture 134 Preparing the product for labeling

In the illustrated example, unfold the glasses [7] and place the temple in the slot [6] of the
grey support. Hold the product firmly with one hand.

6 7

Configuration in
the picture: FL4050
right-hand version
with rollers for
Picture 135 Preparing the product for labeling
300 mm reels.

English | Version 1.0 | FL4050 | 175

 Press the foot pedal [5] or the light button [6] trigger to start label application.

Picture 136 Product labelling - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

176 | FL4050 | Version 1.0 | English

As the clamps close to apply the label around the eyeglass temple, the screen will display ATTENZIONE
for a fraction of a second:

AE4080.t10 C0 00000
PLATE EXTENSION
Prestare attenzione
and right after:
alle dita durante la
fase di chiusra del
AE4080.t10 C0 00000 piattello a pinza.
WAIT DELAY 001

Picture 137 Product labelling - Step 2

The clamps will open and the arm will retract. The screen will display:

AE4080.t10 C0 00000
PLATE RETRACTION

The machine will now wait for the second operator to reserve the processing cycle:

AE4080.t10 C0 00000
WAIT CYCLE TRIG 03

The product is correctly labelled and the machine is ready to start a new cycle with the
second operator, required to perform the steps described above.

Configuration in
the picture: FL4050
right-hand version
Picture 138 Labeled product with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 177

 CAUTION
8.9. Processing cycle with single operator
Following are the instructions to use the semi-automatic labeling bench with one operator
and the sequence of an entire label application cycle. Many of the items on the display will
be visible for a very short time. Each subparagraph indicates the task the operator must
carry out.
Do not wear Make sure that the chosen configuration matches the number of operators. Refer to
rings, watches, subparagraph 8.7.1.
necklaces, hanging
identification
badges, etc., during 8.9.1. Scanning the product
the processing
The scanner [3] must detect the barcode that identifies the product to retrieve the
cycle.
information that will be printed on the label.

Picture 139 Barcode scanner

While waiting for the barcode to be scanned, the screen will display:

AE4080.t10 C0 00000
WAITING LABEL

178 | FL4050 | Version 1.0 | English

Place the source with the barcode [4] close to the enabled scanner [3].

4 3

Picture 140 Barcode scanning

The WAITING LABEL status will remain until the management system sends the data to
be printed to the print engine. Once the bar code that identifies the product to be labeled
has been read, the information is sent directly to the print engine. While the label is being
printed, the LCD screen displays:

AE4080.t10 C0 00000
LABEL PRINTING

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 179

 ATTENZIONE The tamp pad vacuum system remains on hold until the printed label is ejected from the
print engine:

AE4080.t10 C0 00000
WAITING VACUUM 006
Pay attention
during the The tamp pad draws the label [5] and the applicator arm rises level with the notch [6] on
extension of the the jig support:
tamp pad. The
extension area
must be clear of any AE4080.t10 C0 00000
object or body part PLATE EXTENSION
that could obstruct
the movement of
the mechanism.
5 6

Picture 141 Clamp tamp pad extension

The machine will wait for the application trigger to be sent by the operator either by
pressing the foot pedal or the light button:

AE4080.t10 C0 00000
WAIT CYCLE TRIG 01

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

180 | FL4050 | Version 1.0 | English

 8.9.2. Product labeling
Place the product to be labeled [7] on the jig as shown.

Picture 142 Preparing the product for labeling

In the illustrated example, unfold the glasses [7] and place the temple in the slot [6] of the
grey support. Hold the product firmly with one hand.

6 7

Configuration in
the picture: FL4050
right-hand version
with rollers for
Picture 143 Preparing the product for labeling
300 mm reels.

English | Version 1.0 | FL4050 | 181

 Press the foot pedal [5] or the light button [6] trigger to start label application.

Picture 144 Product labelling - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

182 | FL4050 | Version 1.0 | English

As the clamps close to apply the label around the eyeglass temple, the screen will display
for a fraction of a second:

AE4080.t10 C0 00000
PLATE EXTENSION
and right after:

AE4080.t10 C0 00000
WAIT DELAY 001

Picture 145 Product labelling - Step 2

The clamps will open and the arm will retract. The screen will display:

AE4080.t10 C0 00000
PLATE RETRACTION

and right after:

AE4080.t10 C0 00000
WAITING LABEL

The product is correctly labeled and the machine is ready to read a new barcode.

Configuration in
the picture: FL4050
Picture 146 Labeled product right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 183

 8.10. The various modes of the labeling bench
The FL4050 semi-automatic labeling bench has several modes. Here is a brief overview of
the machine status with a description of the condition.

8.10.1. Machine off-line (Stand-by)

The motors are in torque, the compressed air tank is full, the solenoid valves are energized,
the dancer roller of the unwinder and the rewinder are tensioned and the arm of the
applicator performs the “homing” cycle. The machine is ready to start the processing cycle.
This status is useful when it is necessary to modify a machine parameter. For example, if
the machine is waiting for a new label:

AE4080.t10 C0 00000
WAITING LABEL

Press [STOP], so the machine enters a STAND-BY condition:

AE4080.t10 87A3
STAND-BY

8.10.2. Machine idle

Press [STOP] again, the machine enters the IDLE condition. The motors are disabled, the
air tank is emptied, and the solenoid valves are de-energized. The screen displays:

AE4080.t10 87A3
PRESS <START>

8.10.3. Machine alarm

If the machine is in an alarm condition, press [START] once the problem has been solved.
The machine is rearmed and switches to the label waiting condition:

AE4080.t10 C0 00000 AE4050.22c C0 00000

ALARM TYPE E00 WAITING LABEL
If [STOP] is pressed while in alarm status, the machine enters the IDLE condition as the
error is considered similar to a STAND-BY status:

AE4080.t10 C0 00000 AE4080.t10 87A3

ALARM TYPE E00 PRESS <START>

184 | FL4050 | Version 1.0 | English

 8.11. Alarm management
8.11.1. Introduction
It may happen that an error occurs during the production cycle. Some of the most common
include vacuum loss or a generic print error. Refer to chapter 11 for diagnostic and
troubleshooting.

8.11.2. Troubleshooting
When an error appears, the display indicates the type of alarm and, to the right, a code that
identifies the error. The first line displays the machine firmware and to the right, the active
cycle and the progressive number of the label counter:

AE4080.t10 C0 00000
ALARM TYPE E00
It is necessary to identify the type of the error and eliminate the cause before the machine
can be rearmed using the [START] button on the display. The alarm condition remains even
if the error has been resolved, until the machine is rearmed.

Picture 147 START button on the LCD display

If the error has been handled correctly and the machine has been rearmed, the message
WAITING LABEL is displayed so a new application cycle can begin:

AE4080.t10 C0 00000
WAITING LABEL

English | Version 1.0 | FL4050 | 185

 8.12. Replacing the label reel
The low label sensor sends a signal to the machine when the label reel reaches a set limit.
The yellow element of the stack lights visually signals that the reel has reached the set limit.
If label application continues and the label reel runs out completely, a PRINTER ERROR is
displayed on the screen since a label can no longer be detected by the printer:

AE4080.t10 C0 00000
PRINTER ERROR

Replace the reel following the procedure described in paragraph 8.4. Restart the machine
by pressing the [START] button on the LCD display to start the processing cycle again:

AE4080.t10 C0 00000
WAITING LABEL

186 | FL4050 | Version 1.0 | English

 8.13. Changing label size WARNING

8.13.1. Introduction
It is possible to print and apply different sized labels with the FL4050 semi-automatic
labeling bench, but it is necessary to change the clamp tamp pad first.
The tamp pads must be ordered from WEBER MARKING SYSTEMS ITALIA. Please provide
the label size that must be applied. The kit includes the new clamp tamp pad, an air assist Before performing
tube, a spacer and four M8 hexagon socket screws. any maintenance
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.
Shut off the main
compressed
air supply line
Picture 148 Included in the clamp tamp pad kit upstream of the
filter regulator.

8.13.2. How to change the clamp tamp pad

The following picture illustrates the position of the protective panel [1] on the labeling
bench that must be removed to change the clamp tamp pad.
Shut off the air from the main compressed air supply line and disconnect the air hose
upstream of the main compressed air line before proceeding.
Use a Philips screwdriver to remove the twelve screws [2] that secure the panel to the
machine..

2 1

Configuration in
the picture: FL4050
right-hand version
Picture 149 Access to the rewinder/unwinder fixing screws with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 187

 Disconnect all connectors attached to the connector panel [3] of the machine. Disconnect
the air hose [4] from the sleeve valve [5].

Picture 150 How to change the clamp tamp pad- Step 1

Two people are required to replace the unwinder and rewinder.

While an operator holds the unwinder/rewinder from the machine front, unscrew the 4 M8
hex socket screws [6] with an Allen key size 6. Do not lose the washers [7].

Configuration in
the picture: FL4050
right-hand version 7 6
with rollers for
300 mm reels. Picture 151 How to change the clamp tamp pad- Step 2

188 | FL4050 | Version 1.0 | English

Slightly distance the unwinder/rewinder assembly [8] from the base plate and insert the
spacer [10], included with the new clamp tamp pad, between the two pieces.

10

9 10 8

Picture 152 How to change the clamp tamp pad- Step 3

Fix the unwinder/rewinder assembly [8] and spacer [10] to the base plate [9] with the four
washers and the 4 M8 hex socket screws [11] supplied with the new clamp tamp pad with.
Use an Allen key size 6.

11 9

Picture 153 How to change the clamp tamp pad- Step 4

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 189

 Remove the jig [12] from the top of the semi-automatic labeling bench.

12

Picture 154 How to change the clamp tamp pad- Step 5

Prepare the new tamp pad [13] and the air assist tube [14]. Unscrew the lock nut [15] from
the old air assist tube with a 14 mm wrench.

13 14

15

Configuration in
the picture: FL4050 Picture 155 How to change the clamp tamp pad- Step 6
right-hand version
with rollers for
300 mm reels.

190 | FL4050 | Version 1.0 | English

Pull the applicator arm to access the clamp tamp pad[16] to be replaced.

16

Picture 156 How to change the clamp tamp pad- Step 7

Mark the top flow regulators [17] and both corresponding 4 mm hoses [18]. Detach the
hoses [18] from the top flow regulators [17] and detach the two 4mm hoses [19] from the
bottom flow regulators [20].

19 20 18 18 19 20 18 17

Picture 157 How to change the clamp tamp pad- Step 8

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 191

 Loosen the screws [21] on the two limit switches [22] with an Allen key size 2.5. Remove the
switches from the bracket.

22 21 21 22

Picture 158 How to change the clamp tamp pad- Step 9

Unscrew the two M6 socket screws [23] with an Allen key size 3.

23 23

Picture 159 How to change the clamp tamp pad- Step 10

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

192 | FL4050 | Version 1.0 | English

Place the new clamp tamp pad [13] on the applicator arm. Screw back the two M6 socket
screws [23], previously removed, with an Allen key size 3.

13

23

23

Picture 160 How to change the clamp tamp pad- Step 11

Slide the two limit switches [22] into the brackets mounted on the cylinders of the new
clamp tamp pad [24].

22 22

Picture 161 How to change the clamp tamp pad- Step 12

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 193

 The clamps [24] of the tamp pad are normally open. Close a clamp by approximately 10°
and slide the limit switch [22] back and forth, until the LED switches. Tighten the screw [21]
of the switch with Allen key size 2.5. Perform the same operation with the second clamp.
When the clamps are open the LED of both switches will be lit.

24

~ 10°

22 21

Picture 162 How to change the clamp tamp pad- Step 13

Connect the unmarked 4 mm hoses [19] to the bottom flow regulators [20]. Connect the
marked 4mm hoses [18] to the top flow regulators [17]. Once the installation of the new
clamp tamp pad is complete, the applicator arm will lower itself into position.

17 20 19 18 19 20 18 17

Picture 163 How to change the clamp tamp pad- Step 14

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

194 | FL4050 | Version 1.0 | English

Mount the new air assist tube [14] and adjust the air flow as explained in subparagraph
8.13.4. Tighten the lock nut [15] with a 14 mm wrench.

14

15

Picture 164 How to change the clamp tamp pad- Step 15

The overall position of the applicator and the application point of the labels has shifted by
8 mm. Therefore, it will be necessary to adjust the position of the gray support [25] on the
jig [12]. Loosen the two socket screws [26] on the bottom of the jig with an Allen key size 3
and slide the gray support [25] 8 mm, as shown in the figure.

12 26 12 25

Picture 165 How to change the clamp tamp pad- Step 16

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 195

 Place the jig back in its place [12].Connect all devices to the connector panel [3], as
described below. Connect the compressed air hose [4] to the sleeve valve [5].

30

12

Picture 166 How to change the clamp tamp pad- Step 17

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

196 | FL4050 | Version 1.0 | English

The following picture illustrates the connector panel of the unwinder/rewinder. A table
summarizes the connections:

2
8

3
10

11

12
4

5
13

Picture 167 FL4050 connector panel

1. Printer - Print engine connector

2. Applicator - Applicator connector
3. Interface - I/O signals connector
4. USB type B connector
5. ON/OFF switch
6. Printer power supply - IEC 60320 power supply socket for the print
engine
7. Alarm lamp - 8-pin M12 stack lights connector
8. Product sensor P - 5-pin M12 product sensor connector
9. Product sensor S - 5-pin M12 connector (not used)
10. Low label sensor - 5-pin M12 low label sensor connector
11. Ethernet - RJ45 network connector for setup, remote control or service
12. Display - M12 display connector
13. IEC 60320 mains socket with V-Lock fuse holder

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 197

 Table 28 FL4050 semi-automatic labeling bench connections

Module Cable Image reference Connection

Print engine Cable with DB15 Picture 167, point 1 Connect the cable
connector to the DB15 (Printer)
connector on the
connector panel
Power supply Picture 167, point 6 Connect the cable
cable to the IEC 60320
mains socket (Printer
power supply) on the
connector panel of the
unwinder/rewinder
and to the mains
socket on the print
engine
Applicator Cable with DB9 Picture 167, point 2 Connect the cable to
connector the DB9 connector
(Applicator) on the
connector panel
Unwinder/rewinder Cable with DB25 Picture 167, point 3 Connect the cable to
connector the DB25 (Interface)
connector on the
unwinder/rewinder
panel and to the DB25
connector on the
junction box.
Power supply Picture 167, point 13 Connect the cable to
cable the IEC 60320 mains
socket with V-Lock fuse
holder
Stack lights Cable with M12 Picture 167, point 7 Connect the cable
connector to the 8-pin M12
connector (Alarm lamp)
Foot pedal (machine Cable with M12 Picture 167, point 8 Connect the cable
front) connector to the 5-pin M12
connector (Product
sensor P)
Foot pedal (machine Cable with M12 Picture 167, point 9 Connect the cable
rear) connector to the 5-pin M12
connector (Product
sensor S)
Low label sensor Cable with M12 Picture 167, point 10 Connect the cable
connector to the 5-pin M12
connector (Low lable
sensor)
LCD display Cable with M12 Picture 167, point 12 Connect the cable
connector to the 5-pin M12
connector (Display)

198 | FL4050 | Version 1.0 | English

Remount the rear panel [1] of the machine and fix the twelve screws [2] with a Phillips
screwdriver. Connect the machine to the power supply and calibrate the print engine as
described in subparagraph 8.13.3.
2 1

Picture 168 How to change the clamp tamp pad- Step 18

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 199

 CAUTION 8.13.3. Calibrating the print engine
Once the new tamp pad is in place, the new jig is positioned and the reel with the new
labels is mounted, it is necessary to calibrate the printer with the new dimensions. Press
the [CALIBRATE] button [6] and then the button with the [] [2]. The STATUS indicator
light [3] blinks yellow once and the PAUSE indicator light [4] blinks continuously (yellow).
The display [5] has the message LOAD BACKING.
When carrying
out operations as
loading label reels 6 8 9 4 11 3 7 14 15
or installing the
printing ribbon,
do not wear
rings, watches,
necklaces, hanging
identification
badges, etc.

CAUTION

Wait for the print

5 2 3 2 5 1
engine printhead to
cool down before
Picture 169 Print engine control panel
performing any
operation with the
protective panel Turn the printhead release latch to the open position.
open.

Picture 170 Calibrating the print engine - Step 1

Images of the
print engine ZE500
courtesy of Zebra
Technologies

200 | FL4050 | Version 1.0 | English

Extend approximately 8 inches/203 millimeters of media past the peel bar. Remove and
discard the labels from the liner on this exposed media.

Picture 171 Calibrating the print engine - Step 2

Pull the media back into the print engine so that only the liner is between the media
sensors. Press + [6] on the print engine control panel to continue. The control panel will
display REMOVE RIBBON. If printing using thermal transfer, remove the ribbon.
Rotate the printhead-release latch to the closed position, and close the media door.

Images of the
Picture 172 Calibrating the print engine - Step 3 print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 201

 Press [PAUSE] on the control panel of the print engine to begin the media calibration
process. The control panel will display CALIBRATING PLEASE WAIT. When the process
is complete, the control panel will display RELOAD ALL.
Rotate the printhead-release latch to the open position.

Picture 173 Calibrating the print engine - Step 4

Reload the media and ribbon (if used), following instructions from subparagraph 8.5.4.
Rotate the printhead-release latch to the closed position. Close the print engine and press
[PAUSE] to enable printing.

Images of the
print engine ZE500
courtesy of Zebra Picture 174 Calibrating the print engine - Step 5
Technologies

202 | FL4050 | Version 1.0 | English

 8.13.4. Air assist adjustment
It may be necessary to adjust the air assist to properly apply the new labels. The air assist
keeps the label attached to the tamp pad. By covering the entire drilling on the tamp pad,
the vacuum effect is generated so the air blast can apply the label on the product correctly.

1 2 3 3 4 3

Picture 175 Air assist location and description

1. Counter nut that adjusts the orientation of the air assist holes
2. air assist orientation adjustment nut
3. Air assist holes
4. Air assist tube

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 203

 The air assist tube has three small holes that blow air towards the adhesive part of the
label. The air jet must be adjusted and the small holes must be oriented correctly to ensure
that the label adheres properly to the tamp pad.
Lift the jig and place it on the labelling bench top. It is not necessary to disconnect the
product sensor cable.
Use a 12mm wrench to adjust the orientation of the holes on the air assist tube. Lock the
lock nut with a 14mm wrench.

Picture 176 Adjusting the orientation of the air assist - Step 1

In general, the orientation of the air assist tube holes [4] should be at about 45 degrees to
the tamp pad[5] and about 10 mm from the edge of the closest edge of the tamp pad to the
printer [6].

10 mm

Configuration in
the picture: FL4050 5 4
right-hand version
with rollers for Picture 177 Adjusting the orientation of the air assist - Step 2
300 mm reels.

204 | FL4050 | Version 1.0 | English

Using a flat-blade screwdriver, adjust the airflow by closing or opening the flow regulator,
located on the back of the machine in correspondence of the air assist tube.

Picture 178 Adjusting the airflow

It is recommended to start with a medium airflow and then reduce it as the holes are
oriented in the correct position.
During the air assist adjustment procedure, the [FEED] button on the print engine can be
used to dispense labels to verify that the setting is correct.

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 205

 8.14. Language setup
8.14.1. Introduction
It is possible to change the language of the LCD display control panel at any time. The
following table provides a list of preloaded languages and their codes. Other languages not
listed are available upon request.

Table 29 Available languages

Language Code On-screen text

English 000
DISPLAY SETTINGS
CHANGE LANGUAGE 000
German 001
LCD-EINSTELLUNG
SPRACHAUSWAHL 001
French 002
REGL. AFFICHEUR
CHOIX LANGUE 002
Dutch 003
DISPLAY-INST.
VERANDER TAAL 003
Norwegian 004
LCD-INNSTILLING
SPRAKVALG 004
Swedish 005
LCD-INSTALLN.
SPRAKVAL 005
Russian 006
HACTP. ДИCПЛEЯ
BЫБOP ЯЗЫKA 006
Polish 007
USTAWIENIE LCD
ZMIANA JEZYKA 007
Spanish 008
AJUSTES PANTALLA
CAMBIO DE IDIOMA 008
Turkish 009
EKRAN AYARLARI
DILI DEGISTIR 009
Portuguese 010
AJUSTAR VISOR
ALTERAR IDIOMA 010
Italian 011
IMPOSTA DISPLAY
CAMBIA LINGUA 011
Czech 012
NASTAVENI LCD
ZMENA JAZYKU 012
Croatian 013
POSTAVKE LCD
PROMJENA JEZIKA 013

206 | FL4050 | Version 1.0 | English

 8.14.2. How to change the language
If the machine has just been turned on, the screen displays:

AE4080.t10 87A3
PRESS <START>

Press the [START] button:

AE4080.t10 C0 00000
WAITING LABLE

Press [STOP] to enter STAND-BY mode:

AE4080.t10 C0 00000
STAND-BY

On the LCD display control panel, simultaneously press the [] and [ENTER] buttons,
indicated in the picture, points [1 and 2]:

1 2

Picture 179  and ENTER buttons

The screen displays:

FUNCTIONS MENU
LABEL COUNTER: 0000

Press the [] button twice. The screen displays:

MENU’ FUNZIONI
DISPLAY SETTINGS

English | Version 1.0 | FL4050 | 207

 Press the [ENTER] button to confirm the selection. The screen displays:

DISPLAY SETTINGS
CHANGE LANGUAGE 000

Press the [ENTER] button again to change the language. Each time the [ENTER]] button is
pressed, the next language will be selected. When the desired language is displayed, press the
[STOP] button to confirm the selection and return to STAND-BY mode. The number on the
second line to the right corresponds to the language code. For a complete list of languages and
codes, please refer to Table 29.

AE4080.t10 C0 00000
STAND-BY

Press the [START] button to start the processing cycle:

AE4080.t10 C0 00000
WAITING LABLE

208 | FL4050 | Version 1.0 | English

 8.15. Turning off the machine
Once the processing cycle is complete, it is possible to shut down the machine. The control
panel will display:

AE4080.t10 C0 00000
WAITING LABEL

Press the [STOP] on the LCD display to switch to STAND-BY mode:

AE4080.t10 C0 00000
STAND-BY

Press [STOP] again to switch to IDLE mode:

AE4080.t10 87A3
PRESS <START>

Turn the switch on the machine to OFF or 0 and close the circuit breaker with
magnetothermal and differential protection located upstream of the line.

8.16. Temporary shut down

If the machine will not be used for more than three months, disconnect the equipment
from the power supply and compressed air line. Carefully clean the machine and cover it
with a waterproof tarpaulin.

English | Version 1.0 | FL4050 | 209

9. MAINTENANCE CAPITOLO
CHAPTER 91
INFORMAZIONI
MAINTENANCE
GENERALI
Page intentionally left blank
 9.1. Introduction to routine maintenance CAUTION

Adequate routine maintenance of the machine is essential to keep it efficient and

guarantees the safety of the operator as well as a longer life of the equipment over time.
The maintenance operations described in this chapter must be carried out by specialized
Please read this
personnel adequately trained by WEBER MARKING SYSTEMS ITALIA. Any maintenance not
user manual
specified in this chapter must be performed directly by WEBER MARKING SYSTEMS ITALIA.
carefully.
The design and materials used to manufacture the FL4050 labeling bench minimize
maintenance.
WARNING
All routine maintenance procedures must be carried out with the machine disconnected from
the power supply and, where required, from the main compressed air supply line. In addition,
authorized maintenance personnel must be equipped with personal protective equipment and
must comply with the safety precautions listed below.
• Before servicing the equipment, make sure it is in a safe condition
• Before performing any maintenance, disconnect the equipment from
the power supply Before performing
• Always fill out the maintenance form with the date, start time, and any maintenance
maintenance performed operation, turn
• Do not wear rings, watches, necklaces, bracelets, loose clothing, etc. the main power
during maintenance operations switch off and
• Always wear personal protective equipment such as gloves, safety lock it to prevent
glasses, and safety shoes unintentional
• Do not use open flames, sharp instruments or pins for maintenance reactivation. If
and when cleaning the machine possible, disconnect
• Once maintenance is complete, remove all of the tools and cleaning the equipment from
rags used the power supply.
Shut off the main
9.2. FL4050 routine maintenance compressed
air supply line
9.2.1. Cleaning the labeling bench upstream of the
Keep the labelling bench and counter flanges clean by using compressed air, at no more filter regulator.
than 2 bar and at a distance of at least 50 cm or a clean, dry, soft microfiber cloth. General
cleaning is recommended on a daily basis. The frequency may vary depending on the
conditions of use of the machine. CAUTION

When servicing
the machine,
do not wear
rings, watches,
necklaces, hanging
identification
badges, etc.
Always wear
personal protective
equipment.

Configuration in
the picture: FL4050
Picture 180 Cleaning the labeling bench right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 213

 9.2.2. Cleaning the jig
Keep the jig clean. The frequency depends on the conditions of use. Lift the jig [1] from its
housing and clean the bottom side from any glue and adhesive residue. Spray a specific
product for label removal and wait a few minutes. Wipe off glue and adhesive residues with
a clean soft microfiber cloth.

Picture 181 Cleaning the jig

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

214 | FL4050 | Version 1.0 | English

 9.2.3. Cleaning the low label sensor
Keep the low label sensor [1] clean for proper machine operation. Cleaning should be
carried out on a weekly basis or when the sensor does not detect the label reel size and
does not signal the low label warning.
Use a clean, dry, soft microfiber cloth or soft-bristled brush to clean the low label sensor [1].

Picture 182 Cleaning the low label sensor

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 215

 9.2.4. Cleaning the rollers
Check weekly that the paper guide rollers [1] and dancer rollers [2] rotate freely. If
necessary, contact the Technical Service Department, as the bearings may be damaged or
the shaft may have been hit and consequently bent.
Inspect all rollers (paper guide and dancers) of the labeling bench on a daily basis, including
the print engine rollers [3] and the peel bar. Check for glue and adhesive buildups. If found,
spray a specific label removal product and wait a few minutes. Use a clean, soft microfiber
cloth to remove the residues.

3 1 2 2

Picture 183 Cleaning the rollers

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

216 | FL4050 | Version 1.0 | English

 9.2.5. Cleaning the spindles and the reel dragging rings
Check the unwinder spindle [1] and the rewinder spindle [2] weekly for glue and adhesive
buildup. If found, spray a label remover and wait a few minutes. Use a clean, soft microfiber
cloth to remove the residues.

1 2

Picture 184 Cleaning the spindles

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 217

 Blow compressed air, at no more than 2 bar and at a distance of at least 50 cm, to remove
core board residues from the dragging rings [3]. Buildup can occur on the retaining dowel
and between the slats [4]. If necessary, slightly loosen the two screws with an Allen key
(size 3) and blow out the buildup with compressed air.
Adjust the slats to reposition the core or label reel as described in subparagraph 8.4.2.

4 4 3

Picture 185 Cleaning the reel dragging rings

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

218 | FL4050 | Version 1.0 | English

 9.2.6. Cleaning and maintenance of the clamp tamp pad
Keep the plate clean by blowing compressed air at no more than 2 bar and at a distance
of at least 50 cm. Check the label application sponges [1] for glue and adhesive build-up. If
any, the sponges must be replaced (please refer to chapter 13).
Peel off the sponge and remove as much glue residue as possible from the clamp [2]. Do
not use sharp tools and do not scratch off the residue. Spray a label remover on the clamp
and wait a few minutes. Remove glue and adhesive residues with a clean soft microfiber
cloth. Attach the new sponges to the clamp with the holes towards the print engine.

Configuration in
Picture 186 Cleaning and maintenance of the clamp tamp pad the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 219

 WARNING
9.3. Compressed air management unit
maintenance
The compressed air management unit is located on the back side of the machine, lower
right. The pressure gauge [2] must be set to a value between 4 and 6 bar. Different
pressure values may adversely affect the system and the quality of label application.
For any corrections, use the air delivery knob [1]. Turn clockwise to increase or
Before performing counterclockwise to decrease pressure.
any maintenance
operation, turn Check for air leaks on a weekly basis. If air leaks are noticed, check if the hoses are properly
the main power connected.
switch off and
lock it to prevent
unintentional 9.3.1. Access to the filter regulator
reactivation. If
possible, disconnect The following picture illustrates the location of the labeling bench protection panel [1] that
the equipment from must be removed to access the compressed air management unit.
the power supply. Disconnect the machine from the power supply and shut the air off from the
Shut off the main main compressed air supply line. Disconnect the air hose upstream of the main
compressed compressed air line.
air supply line Use a Philips screwdriver to remove the twelve screws [2] that secure the panel to the
upstream of the machine.
filter regulator.

2 1

Picture 187 Access to the compressed air management unit

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

220 | FL4050 | Version 1.0 | English

 9.3.2. Discharging condensation from the filter regulator
The filter regulator has a transparent cup that allows inspection of the level of
condensation inside the filter housing. The inspection must be carried out every six
months. More or less frequent inspections depend on the environmental operating
conditions.
When a level of about 10 mm below the filter is reached, open the discharge screw by
turning it clockwise to drain the water. Once the cup has been emptied, tighten the
discharge screw by turning it counterclockwise.

10 mm

Picture 188 Condensation discharge

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 221

 9.3.3. Replacing the filter cartridge
It is necessary to replace the filter cartridge [1] every 2 years or when the pressure drops
by 1 bar to prevent damage to the machine.
To replace the cartridge, unscrew the filter cup [2] clockwise. Unscrew the filter plate [3]
clockwise and remove the used cartridge. Grasp the new cartridge by the lower end and
insert it in place. Screw the filter plate back on, counterclockwise. Screw the filter cup back
in place.
Connect the 8 mm hose upstream of the main compressed air supply line. Pressurize the
system slowly and adjust the pressure as indicated in subparagraph 9.3.4.

Picture 189 Replacing the filter cartridge

The filter cartridge for the LFR-1/4-D-MINI filter reducer can be ordered directly from Festo
(http://www.festo.com) as part number 363665. In any case, please check the compatibility
of the replacement part.

222 | FL4050 | Version 1.0 | English

 9.3.4. Pressure adjustment
To adjust the pressure, pull the pressure adjustment knob upward to disengage the anti-
torsion guard. Turn the knob fully counterclockwise (“-” sign). When the stop is reached, the
minimum outlet pressure is set. Slowly turn the pressure adjustment knob clockwise (“+”
sign) until the pressure of 6 bar is reached. Once the correct pressure is set (value between
4 and 6 bar), push the pressure adjustment knob down to engage the anti-torsion guard.

- +

Picture 190 Pressure adjustment

English | Version 1.0 | FL4050 | 223

 CAUTION
9.4. Print engine maintenance
Regular cleaning of the print engine keeps print quality high. For more information, please
refer to the manufacturer’s manual included in the delivery.
Use only the indicated cleaning products.

When performing
operations such as 9.4.1. Cleaning the external parts
loading the media
or installing the Clean the external surfaces of the print engine with a clean, dry microfiber cloth. Use a
printing ribbon, mild detergent solution for stubborn dirt.
do not wear
Do not use solvents or corrosive/abrasive cleaning products.
rings, watches,
necklaces, hanging
identification
badges, etc.

Picture 191 Zebra ZE500 print engine

9.4.2. Cleaning the media compartment

Open the print engine protection hatch. Remove any buildup of dirt and filaments from
inside the print engine using a soft brush and/or an industrial vacuum cleaner. Inspect this
area each time a new ribbon is loaded.

Images of the
print engine ZE500
courtesy of Zebra
Technologies Picture 192 Opening the print engine

224 | FL4050 | Version 1.0 | English

 9.4.3. Cleaning the printhead and the platen roller CAUTION

Regular cleaning can extend the life of the printhead and platen roller. It is recommended
that you clean the printhead, platen roller, and pinch roller in the following situations:
• when CLEAN HEAD NOW appears on the print engine display Wait for the
• Direct Thermal Print Mode: after every roll of labels or 500 ft (150 m) of printhead to cool
fanfold labels before performing
• Thermal Transfer Print Mode: after every roll (1500 ft or 450 m) of ribbon any operation with
the protective hatch
open.
If the print quality is inconsistent, such as blank or light areas, clean the printhead more
often. Clean the rollers if there are any problems with the movement of the media.
Switch off the print engine by pressing the switch in point 11 of Picture 106 to clean the
printhead and rollers. Open the print engine hatch. Rotate the printhead release latch to
the open position and remove the media and ribbon from the print engine.

Picture 193 Cleaning the printhead and platen roller - Step 1

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 225

 Use the print engine maintenance kit (for more information, please refer to the
manufacturer’s manual included in the delivery) or a solution consisting of 90% isopropyl
alcohol and 10% deionized water. Moisten a cotton swab and rub the printing elements [1]
from end to end. Wait for the solution to evaporate.
Use a clean, dry lint-free cloth moistened with alcohol to clean the platen roller [2], the
pinch roller and the peel roller. Rotate the rollers while you perform cleaning.
Reload the media and ribbon as described in subparagraph 8.5.4 and in subparagraph
8.5.5 or refer to the manufacturer’s manual included in the delivery. Once cleaning is
complete, lower the printhead release lever and close the protection hatch.

Picture 194 Cleaning the printhead and platen roller - Step 2

Images of the
print engine ZE500
courtesy of Zebra
Technologies

226 | FL4050 | Version 1.0 | English

 9.4.4. Replacing the printhead CAUTION

Some parts of the print engine, such as the printhead and the platen roller, wear out over
time and can be easily replaced. To replace the printhead, open the print engine protection
hatch. Loosen the screw [1] that secures the printhead to the print mechanism [2].
Wait for the
printhead to cool
before performing
any operation with
the protection
hatch open.

2 1

Picture 195 Replacing the printhead - Step 1

Rotate the printhead release latch [3] to open position to lift the print mechanism [2] and
access the printhead.

3 2 Images of the
print engine ZE500
Picture 196 Replacing the printhead - Step 2 courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 227

 Unplug the two connectors [4]. Replace the printhead [5] and reconnect the cables.

Picture 197 Replacing the printhead - Step 3

Once the printhead has been replaced, rotate the printhead release latch to close the
mechanism, tighten the screw [1] and close the print engine protection hatch.

The Zebra ZE500 print engine printhead can be ordered from a Zebra reseller
(http://www.zebra.com).

Images of the
print engine ZE500
courtesy of Zebra
Technologies

228 | FL4050 | Version 1.0 | English

 9.4.5. Replacing the platen roller CAUTION

To replace the platen roller, open the print engine protection hatch. Turn the printhead
release latch to open position to raise the print mechanism.
Wait for the
printhead to cool
before performing
any operation with
the protection
hatch open.

Picture 198 Replacing the platen roller - Step 1

Images of the
print engine ZE500
courtesy of Zebra
Technologies

English | Version 1.0 | FL4050 | 229

 Slightly loosen the screw [2] with a Torx T10 insert and rotate the block [3] 180 degrees,
towards the platen roller [1]. The flat part of the block allows the platen roller to be
removed from its housing. Replace the platen roller and rotate the block [3] 180 degrees
again, so that the round part is over the platen roller bearing. Re-tighten the screw [2] with
the T10 insert, lower the printhead release latch again to close the print engine protection
hatch.

1 3 2

Picture 199 Replacing the platen roller - Step 2

The Zebra ZE500 print engine platen roller can be ordered from a Zebra reseller
Images of the
(http://www.zebra.com).
print engine ZE500
courtesy of Zebra
Technologies

230 | FL4050 | Version 1.0 | English

 9.5. Routine maintenance plan
The following table lists the routine maintenance operations and frequency:
Table 30 Maintenance plan

Procedure

Every six
Monthly

or more
months
Weekly

Yearly
Daily
Cleaning the labeling bench 3
Clean the jig and product sensor 3
Clean the low label sensor 3
Clean the rollers 3
Clean the spindles and reel dragging rings 3
Clean the applicator clamp tamp pad When needed
Check the condensation in the filter regulator 3
Replace the filter cartridge 3
Clean the external parts of the print engine 3
Clean the print engine media compartment When replacing the ribbon
Clean the printhead and platen roller Follow the instructions in
subparagraph 9.4.3
Replace the printhead When needed
Replace the platen roller When needed

English | Version 1.0 | FL4050 | 231

 CAUTION
9.6. Introduction to extraordinary maintenance
The FL4050 semi-automatic labeling bench is completely modular. It is possible to remove
the individual modules of the machine and send them to WEBER MARKING SYSTEMS ITALIA
for repair so they can be re-installed once repaired.
Please read this
user manual
carefully.

Stack lights
WARNING Barcode
LCD scanner
display Low label
sensor

Before performing
Unwinder/
any maintenance rewinder
operation, turn module
the main power Clamp
tamp pad
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.
Shut off the main
compressed
air supply line
upstream of the
filter regulator.

CAUTION

Paper guide
Electric rollers
applicator
Print
engine
When servicing
the machine, Picture 200 FL4050 semi-automatic labeling bench
do not wear
rings, watches,
necklaces, hanging All extraordinary maintenance procedures must be carried out with the machine disconnected
identification from the power supply line and, where required, from the main compressed air supply line.
badges, etc. In addition, authorized maintenance personnel must be equipped with personal protective
Always wear equipment and must comply with the safety precautions listed below.
personal protective
equipment. • Before servicing the equipment, make sure it is in a safe condition
• Before performing any maintenance, disconnect the equipment from
the power supply
• Always fill out the maintenance form with the date, start time, and
maintenance performed
• Do not wear rings, watches, necklaces, bracelets, loose clothing, etc.
during maintenance operations
• Always wear personal protective equipment such as gloves, safety
glasses, and safety shoes
• Do not use open flames, sharp instruments or pins for maintenance
and when cleaning the machine
Configuration in
• Once maintenance is complete, remove all of the tools and cleaning
the picture: FL4050
rags used
right-hand version
with rollers for
300 mm reels.

232 | FL4050 | Version 1.0 | English

 9.7. FL4050 extraordinary maintenance WARNING

9.7.1. Access to module mounting points

The following picture illustrates the position of the labeling bench protection panel [1] that
must be removed to replace the various modules that compose the machine.
Disconnect the machine from the main power supply.
Before performing
Use a Phillips screwdriver to remove the twelve screws [2] that fasten the protective panel any maintenance
[1] to the labeling bench. operation, turn
the main power
switch off and
2 1 lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.

Picture 201 Access to module mounting points

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 233

 WARNING 9.7.2. Replacement of the LCD display
Make sure the machine is disconnected from the power supply.
Disconnect the M12 connector of the LCD display from the connector panel (Display).

Before performing
any maintenance
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.

Picture 202 Replacement of the LCD display - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

234 | FL4050 | Version 1.0 | English

Unscrew the two hex screws [1] with a size 10 wrench. Do not to lose the washers [2]
located between the LCD display and the support bracket [3].

1 2 3 2 1

Picture 203 Replacing the LCD display - Step 2

Remove the faulty LCD display [4]. The cable must be carefully pulled out of the hole [5] on
the polycarbonate panel. Insert the cable of the new LCD display into hole [5].
Fit the display into the bracket and screw it back on, making sure to place the washers
between the display and the support bracket. Connect the cable with the M12 connector to
the connector panel (Display).
The LCD display does not need to be configured.

5 5 3
Configuration in
the picture: FL4050
Picture 204 Replacement of the LCD display - Step 3
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 235

 WARNING 9.7.3. Replacement of the low label sensor
Make sure the machine is disconnected from the power supply.
Disconnect the M12 connector of low label sensor from the connector panel (Low label
sensor).

Before performing
any maintenance
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.

Configuration in Picture 205 Replacement of the low label sensor - Step 1

the picture: FL4050
right-hand version
with rollers for
300 mm reels.

236 | FL4050 | Version 1.0 | English

Remove the two hex socket screws [1] with an Allen key size 2.

1 1

Picture 206 Replacement of the low label sensor - Step 2

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 237

 Remove the faulty low label sensor, support bracket and cable and replace the assembly
with a new one.
Connect the cable with M12 connector to the connector panel (Low label sensor).

Picture 207 Replacement of the low label sensor - Step 3

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

238 | FL4050 | Version 1.0 | English

 9.7.4. Replacement of the stack lights WARNING

Make sure the machine is disconnected from the power supply.

Disconnect the stack lights M12 connector from the connector panel. (Alarm lamp).

Before performing
any maintenance
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.

Picture 208 Replacement of the stack lights - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 239

 Unscrew the 2 M6 hex socket screws [1] with an Allen key size 4 and remove the faulty stack
lights. Remove the two N10-M6 hammer nuts.

1 1

Picture 209 Replacement of the stack lights - Step 2

Slightly screw in the two hex socket screws [1] to the two hammer nuts [2]. Do not tighten
them.

Configuration in
the picture: FL4050
right-hand version 1 1 2 2
with rollers for
300 mm reels. Picture 210 Replacement of the stack lights - Step 3

240 | FL4050 | Version 1.0 | English

Insert the hammer nuts into the groove of the aluminum extrusion and tighten the two hex
socket screws with an Allen wrench size 4.
Connect the stack lights M12 connector to the connector panel (Alarm lamp).
The stack lights do not need to be configured.

1 1

Picture 211 Replacement of the stack lights - Step 4

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 241

 WARNING 9.7.5. Replacement of the unwinder and rewinder
Make sure the machine is disconnected from the power supply.

Two people are required to replace the unwinder and rewinder.

Disconnect all of the cables from the connector panel on the back of the machine.

Before performing While an operator holds the unwinder/rewinder from the machine front, unscrew the 4 M8
any maintenance hex socket screws [1] with an Allen key size 6. Do not lose the washers [2].
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.

2 1 1 1 1

Configuration in
Picture 212 Replacement of the unwinder and rewinder - Step 1
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

242 | FL4050 | Version 1.0 | English

Remove the faulty unwinder/rewinder [3] and replace it with a new one.

Picture 213 Replacement of the unwinder and rewinder - Step 2

With the help of an operator, screw the new unwinder/rewinder to the base plate, using the
screws previously removed. Use the holes indicated in the picture [4].

Picture 214 Replacement of the unwinder and rewinder - Step 3

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 243

 Reconnect all previously disconnected cables.
The unwinder/rewinder is delivered fully configured by WEBER MARKING SYSTEMS ITALIA.
The following picture illustrates the connector panel of the unwinder/rewinder. A table
summarizes the connections:

2
8

3
10

11

12
4

5
13

Picture 215 FL4050 connector panel

1. Printer - Print engine connector

2. Applicator - Applicator connector
3. Interface - I/O signals connector
4. USB type B connector
5. ON/OFF switch
6. Printer power supply - IEC 60320 power supply socket for the print
engine
7. Alarm lamp - 8-pin M12 stack lights connector
8. Product sensor P - 5-pin M12 product sensor connector
9. Product sensor S - 5-pin M12 connector (not used)
10. Low label sensor - 5-pin M12 low label sensor connector
11. Ethernet - RJ45 network connector for setup, remote control or service
12. Display - M12 display connector
13. IEC 60320 mains socket with V-Lock fuse holder

244 | FL4050 | Version 1.0 | English

Table 31 Summary of the necessary connections

Module Cable Image reference Connection

Print engine Cable with DB15 Picture 215, point 1 Connect the cable
connector to the DB15 (Printer)
connector on the
connector panel
Power supply Picture 215, point 6 Connect the cable
cable to the IEC 60320
mains socket (Printer
power supply) on the
connector panel of the
unwinder/rewinder
and to the mains
socket on the print
engine
Applicator Cable with DB9 Picture 215, point 2 Connect the cable to
connector the DB9 connector
(Applicator) on the
connector panel
Unwinder/rewinder Cable with DB25 Picture 215, point 3 Connect the cable to
connector the DB25 (Interface)
connector on the
unwinder/rewinder
panel and to the DB25
connector on the
junction box.
Power supply Picture 215, point 13 Connect the cable to
cable the IEC 60320 mains
socket with V-Lock fuse
holder
Stack lights Cable with M12 Picture 215, point 7 Connect the cable
connector to the 8-pin M12
connector (Alarm lamp)
Foot pedal (machine Cable with M12 Picture 215, point 8 Connect the cable
front) connector to the 5-pin M12
connector (Product
sensor P)
Foot pedal (machine Cable with M12 Picture 215, point 9 Connect the cable
rear) connector to the 5-pin M12
connector (Product
sensor S)
Low label sensor Cable with M12 Picture 215, point 10 Connect the cable
connector to the 5-pin M12
connector (Low lable
sensor)
LCD display Cable with M12 Picture 215, point 12 Connect the cable
connector to the 5-pin M12
connector (Display)

English | Version 1.0 | FL4050 | 245

 9.7.6. Replacement of the paper guide rollers
Unscrew the M5 hex socket screw [2] of the paper guide roller [1] with an Allen key size 4.
Do not lose the washer.

Picture 216 Replacement of the paper guide rollers - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

246 | FL4050 | Version 1.0 | English

Replace the roller and tighten the M5 hex socket screw [1] and washer to secure it.

Picture 217 Replacement of the paper guide rollers - Step 2

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 247

 WARNING 9.7.7. Replacement of the print engine
Make sure the machine is disconnected from the power supply.
Two people are required to replace the print engine.
Disconnect the DB25 connector and the power supply cable from the print engine.

Before performing
any maintenance
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.

Picture 218 Replacement of the print engine - Step 1

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

248 | FL4050 | Version 1.0 | English

Unscrew the five M5 hex socket screws [1] with an Allen key size 4.

1 1

1 1 1

Configuration in
the picture: FL4050
Picture 219 Replacement of the print engine - Step 2 right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 249

 With the help of an operator, remove the faulty print motor [2] from its housing and replace
it with a new one. Screw back the five M5 hex socket screws with an Allen key size 4.
Connect the power supply cable and the cable with the DB15 connector to the print engine.

Picture 220 Replacement of the print engine - Step 3

It is not necessary to configure the print engine if ordered from WEBER MARKING SYSTEMS
ITALIA.
Otherwise, it is necessary to configure some minimum parameters so the print engine
works with WEBER MARKING SYSTEMS ITALIA applicators:

Table 32 Minimum parameters necessary for the print engine to properly work

Parameter Value
PRINT MODE APPLICATOR
APPLICATOR PORT MODE 1
START PRINT SIGNAL LEVEL MODE
PRINT METHOD Specify whether direct thermal printing or thermal transfer will be
used depending on the type of label. For more information refer
to subparagraph 8.5.3.

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

250 | FL4050 | Version 1.0 | English

 9.7.8. Replacement of the applicator WARNING

Make sure the machine is disconnected from the power supply.

Shut off the air from the main compressed air supply line and disconnect the air hose
upstream of the main compressed air line before proceeding.
Two people are required to replace the applicator.
Before performing
Disconnect the DB9 connector of the applicator (Applicator) from the connector panel.
any maintenance
operation, turn
the main power
switch off and
lock it to prevent
unintentional
reactivation. If
possible, disconnect
the equipment from
the power supply.
Shut off the main
compressed
air supply line
upstream of the
filter regulator.

Configuration in
the picture: FL4050
Picture 221 Replacement of the applicator - Step 1 right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 251

 Remove the jig out of its housing.

Picture 222 Replacement of the applicator - Step 2

Disconnect the air assist 4mm blue hose [1] and the applicator 8mm compressed air hose [2].

Configuration in
the picture: FL4050 1 2
right-hand version
with rollers for Picture 223 Replacement of the applicator - Step 3
300 mm reels.

252 | FL4050 | Version 1.0 | English

Measure and write, on a piece of paper, the distance between the machine plate and the
applicator. The “X” measurement, shown in the picture, will be the reference to reposition
the new applicator.

Picture 224 Replacement of the applicator - Step 4

With the help of an operator, remove the two screws [3] that fix the applicator to the
bracket with an Allen key size 6.

3 3 Configuration in
the picture: FL4050
Picture 225 Replacement of the applicator - Step 5 right-hand version
with rollers for
300 mm reels.

English | Version 1.0 | FL4050 | 253

 Remove the faulty applicator [4] and replace it with a new one. Screw the new applicator to
the bracket with the previously removed screws. Do not tighten the screws.

Picture 226 Replacement of the applicator - Step 6

Configuration in
the picture: FL4050
right-hand version
with rollers for
300 mm reels.

254 | FL4050 | Version 1.0 | English

Adjust the position of the applicator, moving as shown in the picture. The position of the
applicator from the plate must correspond to the distance “X”, previously written. Tighten
the screws [3].

3 3

Picture 227 Replacement of the applicator - Step 7

Reconnect the air assist hose [1] and the compressed air hose [2]. Replace the jig in its
housing and reconnect the cable with the DB9 connector of the applicator to the connector
panel of the machine.
The applicator does not need to be configured.

Configuration in
the picture: FL4050
1 2
right-hand version
with rollers for
Picture 228 Replacement of the applicator - Step 8
300 mm reels.

English | Version 1.0 | FL4050 | 255

 CHAPTER
CAPITOLO101
10. USER MANUAL REVISIONS
USER
INFORMAZIONI
MANUAL REVISIONS
GENERALI
Page intentionally left blank
 10.1. User manual revisions
The following table lists the release date and the revisions made to the user manual.

Machine: FL4050 Manual release date: February 28, 2022

Release Version Modified Summary of the revision
date section
28/02/2022 1.0 - User manual version 1.0 released

English | Version 1.0 | FL4050 | 259

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262 | FL4050 | Version 1.0 | English

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English | Version 1.0 | FL4050 | 263

11. DIAGNOSTICSTROUBLESHOOTING
CAPITOLO 1
AND TROUBLESHOOTING
DIAGNOSTICSINFORMAZIONI
AND TROUBLESHOOTING
GENERALI
Page intentionally left blank
 11.1. FL4050 diagnostics
11.1.1. Error management
When an error condition is detected, the machine stops the current cycle and goes into
ALARM condition. The green indicator light turns off and the red one lights on, until the
operator resets the fault/error and manually re-arms the machine by pressing the [START]
button on the LCD display.
The following table lists the possible errors and the probable cause. Not all errors are
applicable to the FL4050 semi-automatic labeling bench.

Table 33 Error management

Code Error name Description Possible cause

E01 NOT Indicates that one of the The probable cause is due to a
RESPONDING processors of an external connection problem (typically
peripheral device (such when the applicator cable is
as the applicator) is not disconnected), or a hardware
responding to commands failure. The lack or removal of
from the unwinder/rewinder the display does not generate
this error, but simply excludes
it from the system without
affecting operations
E02 PARAMETERS If the message is displayed Possible reliability problems with
ERROR immediately after a normal the internal memory of the main
start-up, the verification of board, especially if the message
the machine parameters is frequent. It is, however, normal
failed to receive this message when
rebooting after resetting to the
default configuration, or after
remote configuration: in this case
the message indicates that the
configuration has been changed
E03 LOW PRESSURE The air supply pressure is If the supply pressure is within
not within the specified the range, it may depend
E04 HIGH
range for proper machine on a failure of the internal
PRESSURE
operation pressure sensor, located on the
applicator control board
E05 HOME NOT The sensor with the “home” The problem can be caused
FOUND position (fully retracted by a mechanical issue, which
stroke) of the tamp pad prevents the tamp pad from
did not trigger during the fully retracting, or a pneumatic
retraction phase issue where the cylinder force
is insufficient. Other causes
are misalignment of the “home”
sensor or a hardware defect
E06 HOME ERROR The “home” sensor did not The problem may be caused by a
deactivate within the time mechanical issue, which prevents
limit configured at the the tamp pad from extending,
beginning of the tamp pad or by a pneumatic issue where
extension phase the cylinder force is insufficient.
This error may also appear if
the applicator stroke loses its
“home” position. The same error
is shown if the operator manually
interrupts the “homing” phase by
pressing the STOP button

English | Version 1.0 | FL4050 | 267

 Code Error name Description Possible cause
E07 TRIGGER The message can be This error also occurs when the
ERROR generated only if the primary or secondary product
trigger status control has sensor activates before the
been enabled. It means proximity sensor during a
that the selected trigger frontal application cycle, or in
has not transitioned to the case of a two-sided application
inactive condition since the with dual tamp pad action.
last activation, or that it If the machine is configured as
was activated too early, so a downstream unit in a tandem
that the applicator could configuration, this error can
not recognize the active also mean that the product
transition count between the upstream
and downstream devices is
going below zero, or above the
maximum permitted
E08 PRINTER A print engine error signal Please refer to the print engine
ERROR was detected or the PRINT diagnostics
signal was active before
receiving the next label
request
E09 MISSING The label was not printed This error occurs if CYCLE
LABEL within the configured time OPTION +16 has been enabled
limit to check for proper label
application. If the label remains
on the tamp pad after the
retraction, the label is missing
on the current product is
reported.
The error occurs if the label is
still on the belt at the end of the
application cycle, if the machine
is configured as a belt applicator
and the “Check Label Presence
After Application” option is
enabled
E10 INSUFF. The specified vacuum level It is normally caused by an
VACUUM was not detected within the incorrect positioning of the
configured time limit during label on the tamp pad, due to
the label suction phase an incorrect adjustment of the
air-assist. It may also be caused
by an air leak in the pneumatic
circuit. In this case a sufficient
vacuum level is not reached
in the tamp pad. A possible
malfunction of the vacuum
generator or of the vacuum
sensor on the control board of
the applicator is also possible
E11 VACUUM LOST After the initial detection of It may be caused by an
the presence of the label on unexpected removal of the
the tamp pad, the vacuum label, or by a problem in the
level dropped pneumatic circuit

268 | FL4050 | Version 1.0 | English

Code Error name Description Possible cause
E12 MISSING BLOW An unusually weak pressure May be caused by a malfunction
spike was detected in in the pneumatic circuit
the tamp pad during the
blasting phase
E13 PEAK BLOW An unusually high-pressure May be caused by a malfunction
PRESS. spike was detected in in the pneumatic circuit, often
the tamp pad during the due to an obstruction, like a
blasting phase label stuck on the tamp pad
E14 PROXIMITY The variable stroke sensor It may be caused by the lack
ERROR (mounted on the tamp of the product or if the stoke
pad) has not detected the is insufficient to reach the
tamp pad approaching product. It may also be caused
the product surface within by interference of the tamp pad
the time-limit configured with an unknown object
(or the maximum stroke
configured, in the case
of an electric applicator)
during the extension
phase. The same message
is also displayed when the
proximity sensor activates in
advance at the beginning of
the extension phase
E15 WRONG This message is generated when an operator attempts to
PASSWORD access a password-protected feature without entering the
correct password
E16 BARCODE READ The external barcode It can be caused by a low print
ERR scanner, interfaced to the quality of the bar code or by
machine, was not able to light reflections on the label.
correctly read the applied Another possible cause is an
label after the programmed incorrect angle of the bar code
number of attempts reader
E17 MAX LBL The predefined maximum It can only happen on machines
REJECTS number of consecutive or equipped with RFID-ready print
cumulative rejected RFID engines or a barcode scanner
tags or barcodes has been and the appropriate null label
reached rejection device, if configured
correctly
E18 DOOR NOT The automatic door did not It can be caused by a
OPENING open within the specified mechanical block
maximum time limit
E19 EMERGENCY The emergency stop button has been pressed or the safety
STOP access switch has been opened. The error can only be
generated if the machine is equipped with the appropriate
devices and is configured correctly.
The same error is shown if the supply voltage falls below the
configured threshold

English | Version 1.0 | FL4050 | 269

 Code Error name Description Possible cause
E20 REWINDER The arm of the rewinder It can be caused if the scrap
TIMEOUT dancer roller has not been collection core has not been
tensioned to the correct properly clamped on the
working position rewinder spindle, causing it
to spin freely, or if the liner
breaks. It can also be caused
by a hardware problem related
to the motor, or the dancer
roller arm sensor. The error can
only be generated in machine
is equipped with the rewinder
control board and enabled in
the configuration
E21 L.EDGE NOT This message is part of the It can be caused by a problem
FOUND dispensing cycle and may with the sensor or paper feed.
be displayed after a label It also occurs when a label is
has been issued if the label missing from the reel. If the
sensor has not detected the automatic skip missing labels
edge of the following label feature is enabled, this message
may indicate that more than
one label is missing.
If the machine is configured as a
belt applicator, this message is
generated if the label sensor has
not detected the label before
the maximum output length has
been reached.
If the “Detection of spurious
label movements” function is
enabled, the alarm is triggered
by an abnormal movement even
if the label is not moving
E22 UNWINDER This message may appear It can be caused if the label reel
ERROR only if the motorized has not been clamped properly
unwinder is installed and on the unwinder spindle,
enabled in the machine causing it to spin freely, or if
configuration. The message the liner breaks. It can also be
indicates that, for some caused by a hardware problem
reason, the arm of the related to the motor, or the
dancer roller of the unwinder dancer roller arm sensor
has not been tensioned to
reach the correct working
position, or that the initial
detection phase has taken
too long
E23 Not applicable
E24 Not applicable
E25 Not applicable
E26 POSITIONING The machine was unable to It can be caused, for example,
ERR. move the applicator stroke by an impact against the
to the programmed position product to be labeled or against
the mechanical end stop
E27 ETHER This error is generated when the Ethernet Watchdog timer
WATCHDOG expires

270 | FL4050 | Version 1.0 | English

 11.1.2. Faults and malfunctions
The following table lists possible faults and malfunctions. The table allows the user of
the machine to identify the malfunction, describing the possible cause and a number
of solutions to the malfunction. If the problem is not described in the table or it cannot
be solved even if the instructions are followed, please contact the Technical Service
Department of WEBER MARKING SYSTEMS ITALIA.

Table 34 FL4050 semi-automatic labeling bench failures

Problem Possible cause Recommended solution

The machine does not turn Power supply missing Check the power cable and
on the mains voltage supply
Blown fuse Replace the fuse (5 x 20 mm
time-delay 6.3 A)
Internal failure Contact the Technical
Service Department
Irregular paper feed Dirty or damaged rollers Remove glue residues with
a label remover spray as
described in subparagraph
9.2.4
Wrong web path Check that the reel has
been mounted correctly as
described in paragraph 8.4
Check that the web path
has been carried out
correctly as described in
subparagraph 8.4.5
Jammed labels Remove glue residues with
a label remover spray as
described in subparagraph
9.2.4
Unsuitable label type Use appropriate labels
according to the print
engine specifications
Problems with the print Please refer to the print
engine engine diagnostics in
paragraph 11.3
Incorrect air supply Check that the pressure
gauge indicates a value
between 4 and 6 bar
Check the filter cartridge
and replace it if
necessary, as described in
subparagraph 9.3.3
Reset the pressure to zero
and bring it back to a value
between 4 and 6 bar as
described in subparagraph
9.3.3

English | Version 1.0 | FL4050 | 271

 Problem Possible cause Recommended solution
The label is not applied Wrong label size Check that the label has the
correctly correct size
Problems with the Replace the applicator
applicator motor module as described in
subparagraph 9.7.8
Wrong applicator stroke Contact the Technical
Service Department
Incorrect air supply Check that the pressure
gauge indicates a value
between 4 and 6 bar
Check the filter cartridge
and replace it if
necessary, as described in
subparagraph 9.3.3
Reset the pressure to zero
and bring it back to a value
between 4 and 6 bar as
described in subparagraph
9.3.3
The machine does not start Jammed print engine Clear the obstruction and
the application cycle rewind the labels
Please refer to the print
engine diagnostics in
paragraph 11.3
Incorrect print engine Please refer to the print
parameter values engine diagnostics in
paragraph 11.3
Label reel finished Replace the label reel as
described in subparagraph
8.4.3

272 | FL4050 | Version 1.0 | English

Problem Possible cause Recommended solution
Label liner breaks Wrong web path Check that the reel has
been mounted correctly as
described in paragraph 8.4
Check that the web path
has been carried out
correctly as described in
subparagraph 8.4.5
Check the correct web
path on the paper guide
rollers as described in
subparagraph 8.4.5
Burrs or cuts on the silicone Replace the label reel as
liner described in subparagraph
Dents on the label reel 8.4.3

Significant variations in liner

width
Glue residues on the print Clean the peeling blade
engine peeling blade with the print engine
maintenance kit (please
refer to the manufacturer’s
manual) or with a solution
made of 90% isopropyl
alcohol and 10% deionized
water as described in
subparagraph 9.4.3
Check that the label reel
is not damaged, causing
a build-up of glue on the
peeling blade. If necessary,
replace the reel
Unsuitable label type Use appropriate labels
according to the print
engine specifications
The positioning of the label Problems with the vacuum Contact the Technical
on the tamp pad is incorrect generation Service Department
The solenoid valve for Replace the applicator
vacuum generation is not module as described in
working properly subparagraph 9.7.8
Applicator failure

English | Version 1.0 | FL4050 | 273

 Problem Possible cause Recommended solution
Labels do not adhere to the The solenoid valve for Check the compressed air
tamp pad vacuum generation is not supply
working properly Replace the applicator
module as described in
subparagraph 9.7.8
The air assist flow is too Adjust the air assist as
strong or too weak described in subparagraph
8.13.4
Incorrect air assist hole Adjust the air assist as
adjustment described in subparagraph
8.13.4
The solenoid valve for the Replace the applicator
air assist management is module as described in
faulty subparagraph 9.7.8
Air assist air hose is Check and, if necessary,
disconnected, loose or replace or reconnect the 4
broken mm hose
Wrong tamp pad size Fit the correct jig with tamp
compared to the label pad
Wrong label size Use the correct size of
labels for the jig and tamp
pad
Incorrect drilling of the Check that the drilling is
tamp pad entirely covered by the label
Incorrect positioning of the The product has not been Position the product by
label on the product positioned correctly on the placing it against the guides
jig
Misaligned label Check that the reel has
been mounted correctly as
described in paragraph 8.4
Check and adjust the
position of the rubber
guide rings ad described in
subparagraph 8.4.3
The label remains on the No blast takes place Contact the Technical
tamp pad Service Department
The solenoid valve that Replace the applicator
generates the blast is not module as described in
working properly subparagraph 9.7.8
Applicator failure
The label is not printed Label reel finished Replace the label reel as
described in subparagraph
8.4.3
Incorrect print engine Please refer to the print
parameter values engine diagnostics in
paragraph 11.3
Print engine failure Replace the print engine as
described in subparagraph
9.7.7

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 11.2. LCD display diagnostics
11.2.1. Faults, malfunctions and common problems
The following is a list of possible failures, malfunctions and common problems of the
LCD display. The table allows the user to identify the type of malfunction, describing
the possible cause and a series of steps to follow to solve the problem. If the problem
is not described in the table, or if the problem cannot be solved even if you follow
the instructions, please contact WEBER MARKING SYSTEMS ITALIA Technical Service
Department.

Table 35 Common failures and problems of the LCD display

Fault Possible cause Recommended solution

The display does not turn Cable is disconnected or Check that the M12
on connector is not properly connector is properly
connected connected to the connector
panel of the unwinder/
rewinder
Cable is broken or sheared Replace the display,
referring to subparagraph
9.7.2
CPU main board in the Replace the unwinder/
unwinder/rewinder is faulty rewinder, referring to
subparagraph 9.7.5
The display board is faulty Replace the display,
referring to subparagraph
9.7.2
Some characters or parts of The display board is faulty Replace the display,
characters are missing on referring to subparagraph
the display 9.7.2
Display backlight does not The backlight has been When the display is in
work dimmed intentionally or by STAND-BY mode, press the
mistake [] and [ENTER] buttons at
the same time. Press [] two
times: the entry DISPLAY
SETTINGS will be displayed.
Press [ENTER] two times
to confirm the selection.
Press [] once: the entry
LCD BRIGHTNESS will be
displayed. Press [ENTER]; on
the right, a 3-character digit
indicates the brightness of
the display. The last character
blinks. To increase the
value, press []; to decrease
the value, press []. Press
[ENTER] to confirm. The
brightness of the display will
change at the same time. The
maximum value is 040. Press
[STOP] to return to STAND-
BY mode
The display board is faulty Replace the display,
referring to subparagraph
9.7.2

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 Fault Possible cause Recommended solution
LEDs do not light up The display board is faulty Replace the display,
referring to subparagraph
9.7.2
LCD display keys do not Key wear Replace the display,
work The display board is faulty referring to subparagraph
9.7.2
Control panel display The language parameter was When the display is in
messages are shown in an changed intentionally or by STAND-BY mode, press the
unknown language mistake [] and [ENTER] buttons at
the same time. Press [] two
times: the entry DISPLAY
SETTINGS will be displayed.
Press [ENTER] to confirm
the selection. The entry
CHANGE LANGUAGE will
be displayed. Press [ENTER]
to access the menu. Press
[ENTER] again until the
desired language is found.
Press [STOP] to confirm
the entry and to return to
STAND-BY mode

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 11.3. Zebra ZE500 print engine diagnostics
11.3.1. Error messages
When a print engine-related error occurs, these are displayed on the control panel of
the printer. The following are the error messages, possible causes and recommended
solutions. For more information, please refer to the manufacturer’s manual included with
the delivery.

Table 36 Error management

Display/Print Possible cause Recommended solution

engine condition
ERROR CONDITION The printhead was replaced Install a genuine Zebra™
INVALID HEAD with one that is not a printhead
genuine Zebra™ printhead
The ERROR LED flashes
WARNING The “Early Warning for 1. Clean the printhead.
CLEAN PRINTHEAD Maintenance” feature is
2. On the control panel, go
enabled, and the printhead
to the HEAD CLEANED? menu
has reached the end of
item
the specified interval for
cleaning 3. Press [+] to select YES to
reset the “Early Warning for
Maintenance” printhead
cleaning counter
ERROR CONDITION The printhead is not fully Close printhead
HEAD OPEN closed. completely. Please refer to
subparagraph 9.4.3
The print engine stops. The The head open sensor is not Contact the Technical
ERROR LED flashes working properly Service Department
ERROR CONDITION The print engine is set for Install proper media type,
PAPER OUT noncontinuous media, but or reset print engine for
continuous media is loaded current media type and
The print engine stops. The perform calibration. Please
MEDIA LED is on and the refer to subparagraph
ERROR LED flashes 8.5.5
Misaligned media sensor Check position of the media
sensor. Please refer to the
manufacturer’s manual
The print engine is set for Install proper media
noncontinuous media, but type (please refer to
continuous media is loaded subparagraph 8.5.5),
or reset print engine for
current media type and
perform calibration. Please
refer to the manufacturer’s
manual

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 Display/Print Possible cause Recommended solution
engine condition
ERROR CONDITION In thermal transfer mode, Load ribbon correctly.
RIBBON OUT ribbon is not loaded or Please refer to
incorrectly loaded subparagraph 8.5.4
The print engine stops. The In thermal transfer mode, 1. Load ribbon correctly.
RIBBON LED is on and the the ribbon sensor is not Please refer to
ERROR LED flashes detecting ribbon subparagraph 8.5.4
2. Calibrate the print
engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
In thermal transfer mode, 1. Load media correctly.
media is blocking the ribbon Please refer to
sensor subparagraph 8.5.5
2. Calibrate the print
engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
In thermal transfer mode, 1. Print a sensor profile.
the print engine did not Please refer to the
detect the ribbon even manufacturer’s manual
though it is loaded correctly included in the delivery. The
exhausted ribbon threshold
is probably set too high
2. Calibrate the print
engine. Please refer to
subparagraph 8.13.3
and the manufacturer’s
manual. Load print engine
defaults. Please refer to the
manufacturer’s manual
If you are using direct Set the print engine for
thermal media, the print Direct Thermal mode.
engine is waiting for ribbon Please refer to the
to be loaded because it is manufacturer’s manual
incorrectly set for Thermal
Transfer mode

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Display/Print Possible cause Recommended solution
engine condition
WARNING Ribbon is loaded, but the Ribbon is not required with
RIBBON IN print engine is set for direct direct thermal media. If you
thermal mode are using direct thermal
The RIBBON LED is on and media, remove the ribbon.
the ERROR LED flashes This error message will not
affect printing
If thermal transfer media is
being used, which requires
ribbon, set the print engine
for Thermal Transfer
mode. Please refer to the
manufacturer’s manual
THERMISTOR The printhead has a faulty Contact the Technical
FAULT thermistor Service Department

The ERROR LED flashes

WARNING CAUTION
HEAD COLD
An improperly connected printhead data or power
The print engine prints cable can cause this error message. The printhead may
while the ERROR LED be hot enough to cause severe burns. Allow the printhead to
flashes cool down
The printhead temperature Continue printing while
is approaching its lower the printhead reaches
operating limit the correct operating
temperature. If the error
remains, the environment
may be too cold for proper
printing. Relocate the print
engine to a warmer area
The printhead data cable is CAUTION: Turn off the print
not properly connected engine before performing
this procedure. Failure
to do so can damage the
printhead.
1. Turn off the print engine
2. Disconnect and
reconnect the data cable to
the printhead
3. Ensure that the cable
connector is fully inserted
into the printhead connector
4. Turn on the print engine
The printhead has a faulty Contact the Technical
thermistor Service Department

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 Display/Print Possible cause Recommended solution
engine condition
WARNING CAUTION
HEAD TOO HOT
The printhead may be hot enough to cause severe
The print engine stops. burns. Allow the printhead to cool
The ERROR LED flashes The printhead is over Allow the print engine to
temperature cool. Printing automatically
resumes when the
printhead elements cool
to an acceptable operating
temperature
WARNING CAUTION
HEAD COLD
An improperly connected printhead data or power
cable can cause these error messages. The printhead
THERMISTOR may be hot enough to cause severe burns. Allow the printhead
FAULT to cool down
The printhead data cable is CAUTION: Turn off the print
ERROR CONDITION not properly connected engine before performing
HEAD ELEMENT BAD this procedure. Failure
to do so can damage the
The print engine stops. printhead.
The ERROR LED is on. The
print engine cycles through 1. Turn off the print engine
these three messages
2. Disconnect and
reconnect the data cable to
the printhead
3. Ensure that the cable
connector is fully inserted
into the printhead connector
4. Turn on the print engine
The printhead has a faulty Contact the Technical
thermistor Service Department

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Display/Print Possible cause Recommended solution
engine condition
DEFRAGMENTING The print engine is CAUTION: Turn off the print
DO NOT POWER OFF defragmenting engine before performing
memory this procedure. Failure
The print engine stops to do so can damage the
printhead.
Allow the print engine to
finish defragmenting. If
you get this error message
frequently, check your
label formats. Formats that
write to and erase memory
frequently may cause the
printer to defragment often.
Using properly coded label
formats usually minimizes
the need for defragmenting.
If this error message
does not go away, contact
the Technical Service
Department

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 Display/Print Possible cause Recommended solution
engine condition
OUT OF MEMORY There is not enough Free up some of the print
CREATING BITMAP memory to perform the engine’s memory by
function specified on the adjusting the label format
second line of the error or print engine parameters.
OUT OF MEMORY message One way to free up memory
BUILDING FORMAT is to adjust the print width
to the actual width of the
OUT OF MEMORY label instead of leaving
STORING GRAPHIC the print width set to the
default. Please refer to the
OUT OF MEMORY manufacturer’s manual
STORING FORMAT Ensure that the device, such
as a FLASH memory card,
OUT OF MEMORY is installed and not write
STORING BITMAP protected or full
Ensure that the data is
OUT OF MEMORY not directed to a device
STORING FONT that is not installed or is
unavailable
Contact the Technical
Service Department

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 11.3.2. Printing problems
The following table lists possible problems with the print engine and problems related to
print quality, possible causes and recommended solutions. If the problem is not described
in the table or is not solved even after following the instructions, please contact WEBER
MARKING SYSTEMS’ Technical Service Department.

Table 37 Printing problems

Problem Possible cause Recommended solution

General print quality issues The print engine is set at an For optimal print quality,
incorrect print speed set the print speed to the
lowest possible setting for
your application via control
panel, the driver, or the
software. Perform the FEED
Self-Test to determine the
optimal settings for your
print engine. Please refer to
the manufacturer’s manual
for instructions on how to
change the print speed
The combination of labels Switch to a different type
and ribbons used is not of media or ribbon to
correct for the application try to find a compatible
combination
The print engine is set at an For optimal print quality,
incorrect darkness level set the print speed to the
lowest possible setting for
your application via control
panel, the driver, or the
software. Perform the FEED
Self-Test to determine the
optimal settings for your
print engine. Please refer to
the manufacturer’s manual
for instructions on how to
change the print speed
The printhead is dirty Clean the printhead. Please
refer to subparagraph
9.4.3
Incorrect or uneven 1. Position the printhead
printhead pressure toggles correctly. Please
refer to the manufacturer’s
manual
2. Set the printhead
pressure to the minimum
needed for good print
quality. Please refer to the
manufacturer’s manual

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 Problem Possible cause Recommended solution
Loss of printing registration The platen roller, pinch Clean the printhead and
on labels. Excessive vertical roller, or peel roller is dirty rollers. Please refer to
drift in top-of-form subparagraph 9.4.3
registration Media guides are positioned Ensure that the media
improperly guides are properly
positioned. Please refer to
subparagraph 8.5.4 and to
subparagraph 8.5.5
The media type is set Set the print engine for
incorrectly the correct media type
(gap/notch, continuous, or
mark). Please refer to the
manufacturer’s manual
The media is loaded Load media correctly.
incorrectly Please refer to
subparagraph 8.5.4
Long tracks of missing print Print element damaged Contact the Technical
on several labels Service Department
Wrinkled ribbon See wrinkled ribbon causes
and solutions in Ribbon
Problems in subparagraph
11.3.3
Fine, angular gray lines on Wrinkled ribbon See wrinkled ribbon causes
blank labels and solutions in Ribbon
Problems in subparagraph
11.3.3
Printing too light or too dark The media or ribbon is not Replace supplies with those
over the entire label designed for high-speed recommended for high-
operation speed operation
You are using an incorrect Switch to a different type
combination of media and of media or ribbon to
ribbon for your application try to find a compatible
combination
You are using ribbon with Direct thermal media
direct thermal media does not require ribbon.
To determine if you are
using direct thermal media,
perform the label scratch
test. Please refer to the
manufacturer’s manual
Incorrect or uneven 1. Position the printhead
printhead pressure toggles correctly. Please
refer to the manufacturer’s
manual
2. Set the printhead
pressure to the minimum
needed for good print
quality. Please refer to the
manufacturer’s manual

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Problem Possible cause Recommended solution
Smudge marks on labels The media or ribbon is not Replace supplies with those
designed for high-speed recommended for high-speed
operation operation
Misregistration/skips labels The print engine is not Calibrate the print
calibrated engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
Improper label format Check your label format and
correct it as necessary
Misregistration and misprint The platen roller, pinch Clean the printhead and
of one to three labels roller, or peel roller is dirty rollers. Please refer to
subparagraph 9.4.3
Media does not meet Use media that meets
specifications specifications. Please refer
to the manufacturer’s
manual
Vertical drift in top-of-form The print engine is out of Calibrate the print
position calibration engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
The platen roller, pinch Clean the printhead and
roller, or peel roller is dirty rollers. Please refer to
subparagraph 9.4.3
Vertical image or label drift The print engine is using Set the print engine for
non-continuous labels but is the correct media type
configured in continuous (gap/notch, continuous,
mode or mark). Please refer
to the manufacturer’s
manual. Calibrate the print
engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
The media sensor is Calibrate the print
calibrated improperly engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
The platen roller, pinch Clean the printhead and
roller, or peel roller is dirty rollers. Please refer to
subparagraph 9.4.3
Incorrect or uneven 1. Position the printhead
printhead pressure toggles correctly. Please
refer to the manufacturer’s
manual
2. Set the printhead
pressure to the minimum
needed for good print
quality. Please refer to the
manufacturer’s manual
The media or ribbon is Ensure that the media
loaded incorrectly and ribbon are loaded
correctly. Please refer to
subparagraph 8.5.4 and to
subparagraph 8.5.5
Incompatible media Use a liner that meets the
specifications. Make sure
the gap or pitch between
labels is evenly spaced
between 2 and 4 mm

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 Problem Possible cause Recommended solution
The bar code printed on a The print engine is using Perform the FEED Self-Test.
label does not scan non-continuous labels but is Adjust the darkness or print
configured in continuous speed settings as necessary
mode
There is not enough blank Leave at least 1/8 in. (3.2
space around the bar code mm) between the bar code
and other printed areas on
the label and between the
bar code and the edge of
the label
Auto Calibrate failed The media or ribbon is Ensure that the media
loaded incorrectly and ribbon are loaded
correctly. Please refer to
subparagraph 8.5.4 and to
subparagraph 8.5.5
The sensors could not Calibrate the print
detect the media or ribbon engine. Please refer to
subparagraph 8.13.3 and
the manufacturer’s manual
The sensors are dirty or Ensure that the sensors
positioned improperly are clean and properly
positioned
The media type is set Set the print engine for
incorrectly the correct media type
(gap/notch, continuous, or
mark). Please refer to the
manufacturer’s manual

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 11.3.3. Ribbon problems
The following table lists possible problems with the ribbon, possible causes and
recommended solutions. If the problem is not described in the table or is not solved even
after following the instructions, please contact WEBER MARKING SYSTEMS’ Technical
Service Department.

Table 38 Ribbon problems

Problem Possible cause Recommended solution

Broken or melted ribbon Darkness setting too high 1. Reduce the darkness
setting. Please refer to the
manufacturer’s manual for
instructions on changing
the intensity setting
2. Clean the printhead
thoroughly. Please refer to
subparagraph 9.4.3
The ribbon is coated on the Replace the ribbon with
wrong side and cannot be one coated on the correct
used in this print engine side. Please refer to the
manufacturer’s manual
Ribbon slips or does not The ribbon tension is not Change the ribbon tension
advance correctly correct setting. Please refer to the
manufacturer’s manual
Ribbon creases The ribbon is not loaded Load the ribbon
correctly correctly. Please refer to
subparagraph 8.5.4
The writing temperature is To optimize print quality, set
not correct the lowest possible intensity
for your application.
We recommended running
the Self-Test using the FEED
button, as indicated in the
manufacturer’s manual
to determine the optimal
intensity setting.
Please refer to the
manufacturer’s manual for
instructions on changing
the intensity setting
Incorrect or uneven Set the printhead pressure
printhead pressure to the minimum needed for
good print quality. Please
refer to the manufacturer’s
manual
Media not feeding properly; Make sure that media is
“walking” from side to side snug by adjusting the
media guide, or contact
the Technical Service
Department
The printhead or platen Contact the Technical
roller are not installed Service Department
correctly

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 Problem Possible cause Recommended solution
The printer does not detect The printer may have been Calibrate the printer, this
when the ribbon runs out calibrated without ribbon. time using ribbon, or load
In thermal transfer mode, Later, ribbon was printer defaults. Please
the printer did not detect inserted without the user refer to subparagraph
the ribbon even though it is recalibrating the printer or 8.13.3 and the
loaded correctly loading printer defaults manufacturer’s manual

The printer indicates that The print engine was not Calibrate the print
ribbon is out, even though calibrated for the label and engine. Please refer to
ribbon is loaded correctly ribbon being used subparagraph 8.13.3 and
the manufacturer’s manual

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 11.3.4. Communication problems
The following table lists possible communication problems, possible causes and
recommended solutions. If the problem is not described in the table or is not solved even
after following the instructions, please contact WEBER MARKING SYSTEMS’ Technical
Service Department.

Table 39 Communication problems

Problem Possible cause Recommended solution

A label format was sent to The communication Check the print engine
the print engine but was not parameters are incorrect driver or software
recognized. The DATA light communications settings (if
does not flash applicable)
If serial communication is
used, check the serial port
setting. Please refer to the
manufacturer’s manual
If serial communication
is used, be sure to use a
null modem cable or null
modem adapter
Check the printer’s
handshake protocol setting.
The setting used must
match the one being
used by the host computer.
Please refer to the
manufacturer’s manual
If a driver is used, check
the driver communication
settings for your connection
A label format was sent to The serial communication Ensure that the flow control
the print engine. Several settings are incorrect settings match
labels print, then the print Check the communication
engine skips, misplaces, cable length
misses, or distorts the
image on the label Check the print engine
driver or software
communications settings (if
applicable)
A label format was sent to The prefix and delimiter Check the print engine
the print engine but was characters set in the print driver or software
not recognized. The DATA engine do not match the communications settings (if
LED flashes but no printing ones in the label format applicable). Please refer to
occurs the manufacturer’s manual
Incorrect data is being sent Check the communication
to the print engine settings on the computer.
Ensure that they match the
print engine settings
If the problem continues,
check the label format

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 11.3.5. Miscellaneous problems
The following table lists miscellaneous problems, possible causes and recommended
solutions. If the problem is not described in the table or is not solved even after following
the instructions, please contact WEBER MARKING SYSTEMS’ Technical Service Department.

Table 40 Miscellaneous problems

Problem Possible cause Recommended solution

Control panel display The language parameter 1. On the control panel
messages are shown in an was changed through the display, press [SETUP].
unknown language control panel or a firmware
2. Press [] once to move to
command
the LANGUAGE parameter
3. Use [+] or [-] to scroll
through the language
selections. The selections for
this parameter are displayed
in the actual languages to
make it easier for you to find
one that you are able to read
4. Select the correct
language
The display is missing The display may need Contact the Technical
characters or parts of replacing Service Department
characters
Changes in parameter Some parameters are set 1. Check the parameters
settings did not take effect incorrectly and change or reset if
necessary
2. Turn the print engine off
and then on
A firmware command (such Contact the Technical
as device.command _ Service Department
override) turned off
the ability to change the
parameter
A firmware command
changed the parameter
back to the previous setting
There may be a problem
with the main logic board
Non-continuous labels are The print engine was not Calibrate the print
being treated as continuous calibrated for the media engine. Please refer to
labels being used subparagraph 8.13.3
The print engine is Set the print engine for
configured for continuous the correct media type
media (gap/notch, continuous, or
mark). Please refer to the
manufacturer’s manual
All lights are on, but nothing Internal electronic or Contact the Technical
is shown on the display (if firmware failure Service Department
any) and the print engine
stops
Print engine stops while Main logic board failure Contact the Technical
performing the power-on Service Department
self-test

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 11.4. Filter regulator diagnostics
11.4.1. Faults and malfunctions
The table below describes the possible problems with the filter regulator, causes and
recommended solutions. If the problem is not described in the table or if no solution can
be found even if the instructions are followed, please contact WEBER MARKING SYSTEMS
ITALIA technical assistance service.

Table 41 Filter regulator failure and malfunctions

Fault Possible cause Recommended solution

No pressure value displayed Shut-off valve closed Open the shut-off valve
Failure to adjust pressure Adjust the pressure with the
pressure adjustment knob
Defective pressure gauge Replace the pressure gauge
Low flow rate (pressure Dirty filter cartridge Replace the filter cartridge
decreases as compressed Bottleneck between the Check the duct
air is used) shut-off valve and
the maintenance device
Pressure exceeds the set Faulty valve stem in the seal Contact the Technical
operating pressure seat Service Department
Audible leakage from the Damaged valve seat Contact the Technical
adjustment knob Service Department
Audible leakage from the Discharge screw not tight Tighten or replace
discharge screw

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 MACHINE
12. ELECTRICAL AND PNEUMATICCAPITOLO
DIAGRAMS
DIAGRAMS 1
INFORMAZIONI GENERALI
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12.1. Diagrams for the FL4050
12.1.1. Interconnection wiring diagram

Picture 229 Interconnection wiring diagram

English | Version 1.0 | AE4050-LD | 295

 12.1.2. FL4050 wiring diagram

Picture 230 FL4050 wiring diagram

296 | AE4050-LD | Version 1.0 | English

12.1.3. AE4050 pneumatic diagram

PRESSURE VACUUM

APPLICATION TAMP
SV1

SV2
AIR ASSIST

CILINDER TAMP
SV3

SV4

SV5

INDICE DATA FIRMA DESCRIZIONE

MATERIALE T.T. T.S.

DESCRIZIONE TOLL. GENERALE QUANTITA' SCALA

UNI ISO 2768 - 1:1
Pneumatic diagramAE4080 FL DISEGNATO APPROVATO DATA
Danelli 24/07/2019
Phoenix Italia S.r.l. CODICE FORMATO
V. S. Andrea 10
20010 Bareggio MI
Italy
A4

Picture 231 AE4050 pneumatic diagram

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13. SPARE PARTS SPARE
CAPITOLO
PARTS1
INFORMAZIONI GENERALI
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 13.1. AE4050-LD spare parts catalog
The AE4050-LD semi-automatic labeling bench is completely modular. In case of failure,
simply replace the faulty module with a spare one. Please contact our technical service and
send the faulty module to WEBER MARKING SYSTEMS ITALIA for repair.
Jigs and tamp pads vary depending on label size. For labels not listed, please contact our
Technical Service Department.

AE4050-LD semi-automatic labeling bench modules

Item Spare part number Description
40014836 Backlit LCD display 2 x 20 characters (with cable
and M12 connector)

LXFVAS02019 Jig including product sensor (with cable and M12

connector) and drilled tamp pad, suitable for B19
labels (size 43 x 89 mm)
LXFVAS02020 Jig including product sensor (with cable and M12
connector) and drilled tamp pad, suitable for B20
labels (size 43 x 126 mm)
LXFVAS02021 Jig including product sensor (with cable and M12
connector) and drilled tamp pad, suitable
for B21 labels (size 70 x 30 mm) and B31 labels
(size 60 x 33 mm)
LXFVAS02030 Jig including product sensor (with cable and M12
connector) and drilled tamp pad, suitable for B30
(size 41 x 62 mm)
40082380 Low label sensor with bracket. Includes a 1-meter
cable and M12 connector

22702287 Three element stack light (red, yellow green)

including mounting bracket (with cable with M12
connector)

WI4056.380W 180 mm unwinder/rewinder module

WI4050.914 180 mm paper guide roller

21600321 Zebra ZE500 6-inch print engine (200 dpi)

21600325 Zebra ZE500 6-inch print engine (300 dpi)

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 Item Spare part number Description
Contact technical Electric linear applicator with 350 m stroke for
support clamp tamp pads

Contact technical T3 clamp tamp pad kit for flag labels

support

WI4057.901 T17 clamp tamp pad kit for flag labels

WI19072021 Scanner kit. Includes a scanner for barcode

reading and connection cables

WI4057.016A Wired M12 male foot switch

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 Weber Marking Systems Italia S.r.l.

Offices: Via Sant’Andrea 11/b | 20008 Bareggio (MI)

Warehouse: Via Redipuglia 8/b | 20008 Bareggio (MI)
T.: +39 02 8089 8225 | info@webermarking.it | www.webermarking.it