User Manual - ALS 306 / ALS 309
Contents
1. USER MANUAL 051 79 Label Dispenser 300 309 AVERY DENNISON Edition 7 4 2010 Link information to your product 1 1 1 1 1 1 2 1 2 1 1 2 2 1 2 3 1 2 4 2 1 2 1 1 2 1 2 2 1 4 2 1 5 Please note General notes Validity and binding effect of this manual 5 COMENTS seda ra ae aide ees aus en ae ed 5 Technical status seek week woes wok wk week eek 5 Copyright armer ren 5 Manufacturer 0 0 0 een 5 Illustrations and descriptions 6 Signs and symbols 2 222222222 6 Dangers and risk notes 2 222222 6 FONOS aenar 6 Button symbols a na naana aaaea naaa 6 Parameters 0 0 0 0 cee ee eee 6 Supplementary information 6 Safety instructions Information and qualifications 7 Follow the instructions 05 7 Keep the product information athand 7 Ensure the required qualifications are met 7 Operational safety of the unit 8 Proper usage ee eee 8 Protection against injuries by electrical current 8 Protection against injuries by mechanical action 9 Protection against injuries by chemicals 9 Before beginning production 10 Due diligence of the operating company and the service technician 00 eee eee 10 Due diligence of the user 10 Safety notes on the unit 11 Product desc2. 2 PRODUCT DESCRIPTION 2 2 OPTIONS Printer If necessary you can mount a hot stamp printer not available from Avery Dennison onto the holder rods of the dispensing edge Example of use Printing consecutive numbers onto la bels Applicator If it is not possible to label directly from the dispensing edge you can fit an applicator to the label dispenser Various types of applicators are available that depend on the given requirements Simple applicators can be controlled directly via the PLC signal interface that is available as standard Applicator interface Additional board allows almost all types of applicators to be controlled 2 PRODUCT DESCRIPTION 2 3 OPERATING MODES 2 3 1 Dispensing mode This is the operating mode of the unit when switched on You can carry out the functions listed in the sections below f text such as Prof 5 xxxxxxxx is displayed 1 instead of ONLINE The xxxxxxxx product profile memory location 5 is activated For more information see the Using product profiles section Stopping Continuing the dispensing Stopping the dispensing gt Press the button The dispenser stops One of the two texts appears ONLINE Stopped press NW key to start or ONLINE Stopped remove label press key to start 1 Second line scroll text Continuing the dispensing gt Ifthe lower text is displayed Remove the
3. 4 2 1 Function menu settings Label pitch gt Switch to configuration mode i B Calibrating the label pitch automatically we ar x ri gt Hold down the button for a while longer than two seconds Or Enter the label pitch manually gt Measure the label pitch 57C gt Call the function J J gt Enter the measured value in millimetres C 57 A Label web B Label C Label pitch Label stop position Prerequisites A The label length must be specified The next label to be dispensed waits in the label stop position Here it is useful if the label protrudes over the dispensing edge a little 58 ALS 30x labellers are pre configured for use 1 with the supplied label sensor If this sensor is employed the label stop position setting will only require minimal correction Correcting the default setting gt Call the function gt Increase the value to increase the overhang or lower the value to reduce the overhang 58 Label stop position A The value 0 will cause the label to stop with its front edge directly under the label sensor The front edge of the next label to be dispensed should be flush with the dispensing edge gt Enter the distance 58A between the label sensor and the dispensing edge The front edge of the label to be dispensed should overhang gt Add the length of the overhang to the distance between the label sensor and t
4. N 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL 3 2 4 Splice unit application pemp B j ET 3 Mls gt f The splice unit is an accessory for ALS 30x labellers which are operated with two lateral unwinders The unit S makes it easier to bond start and end of the two label oN webs Thus the label web doesn t have to be newly fed N in Prerequisites lt ALS30x with two laterally mounted unwinders Cable kit for internal outer diameter control for each of the two unwinders connected see chapter Connecting sensors on page 35 Splice unit mounted see service manual chapter Mounting the bonding unit on page 40 47 Material end of the righthand side label roll fixed at the splice unit NY Example The ALS 30x initially operates from the left hand roll gt Fix the material end 47A of the righthand side label roll spare roll using the righthand side clamp bar 47B If the end of label stock on the lefthand side roll is rea ched gt Fix the material end of the lefthand side label roll 48A using the lefthand side clamp bar gt Pull some adhesive tape off the roll 49A and bond both material ends with it gt Cut the adhesive tape flush using a cutter guiding notch gt Open both clamp bars and release the label web gt Make sure that the label web follows the correct path see preceding chapters gt
5. CAUTION A caution indicates risks that can lead to property damage or injuries to persons minor injuries The caution note contains instructions for preventing damages gt Always follow the instructions ALS Figures Texts are accompanied by figures where necessary Figures are indicated using figure numbers in Square brackets A capital letter after a figure number for example 12A refers to a specific section of the figure Generally the label dispenser shown is a right handed version The left handed version is only shown where it is necessary to differentiate between the two Button symbols The buttons of the control panel are depicted as symbols The symbols are depicted with a PLUS SIGN between them if more than one button Is to be pressed G Parameters Parameters are displayed in grey in the text with the following structure Supplementary information The expert symbol indicates actions that are EXPERTS Only to be performed by qualified and specially trained personnel oe The information symbol indicates notes and 1 recommendations as well as additional information J Equipment A Equipment for example lubricants or cleaning agents 1 2 SAFETY INSTRUCTIONS 1 2 1 Information and qualifications Follow the instructions WARNING Safe and efficient operation of the label _ dispenser can only be guaranteed if you observe all necessary information P
6. If none of the above listed actions is successful search for technical assistance 6 OPERATIONAL FAILURES 6 1 STATUS MESSAGES Status Status text 5140 5143 Rewinder Stop Rewinder control Cause Rewinder control During problem free operation 1 the rewind unit dancer arm only moves a minimal distance around the control position This is the position the dancer arm takes up after initialisation of the machine Any force applied that moves the dancer arm from its control position Example The feed motor is blocked the backing paper is not conveyed quickly enough as a result the dancer arm is pulled upwards Example The backing paper is torn the dancer arm springs downwards This message appears when the dancer arm was held against its upper stop for more than two seconds Effect Power to the rewinder motor is switched off so that the rewinder can be turned easily by hand oe This effect is helpful when 1 installing a new label roll because the rewinder can be turned easily Action to take gt Press the I key This reinitialises the dancer arm control the dancer arm moves back into the control position gt Press the I key to confirm the error message 5145 Rewinder full 67 List of error messages This error can only occur if the Fe on to backing paper that had already been wound onto the rewinder The maximum permitted di
7. Light sens type Wenglor 4 Only appears if MACHINE SETUP gt Speed Adaption On 5 Only appears if MACHINE SETUP gt Tandem Operation Master Flipflop master or Slave 6 Only appears if Tandem Operation Master or Master flipflop and if Tandem Synch UDP Tandem Port 7 Only appears if MACHINE SETUP gt OD Sensor mode Error or Warning 8 Only appears if INTERFACE PARA gt NETWORK PARAM gt Time client Enabled 30 ALS 2 4 FUNCTION DESCRIPTIONS SIGNAL INTERFACE continued SERVICE DIAGNOS SERVICE DATA Interface mode gt AI BOARD SIGNAL Service gt MODULE FW VERS Manufacturer gt PLC SIGNALS Serv data reset System version Work place Apply mode Sensor Test System revision Company name Disp end delay Start mode Memory card test System date End pulse width Dwell time Test functions Bootloader gt DISPLAY DATA Blow on time Store diagnosis uMon Display version gt APPLIC SIGNALS Restart delay Data blocks del Applicator int Display serial nr Position timeout Remote disp vers gt OPERATION DATA Serv operations Status outputs Apply comp time Remote disip Apply mode Dwell time gt AI BOARD SIGNAL gt CF CARD SLOT Tot mat length Blow on time Status signals Card in slot Dispensing cycl Restart delay Operation time Posit
8. Threading diagrams 38 Threading the label web at the dispensing BEIGE pastiche che A kh cee Eee ee ee 41 Threading the label web onto the drive roller 42 Threading the label web to the rewinder 42 Splice unit application 43 Mechanical settings Adjusting the unwinder s core diameter 44 Positioning the pressure roller 44 Positioning the label sensor 45 Setting the dancer arm restoring force 45 Operation Start up and shutdown Turning on the unit 46 Starting label dispensing 46 Dispensing with a product sensor 46 Dispensing without a product sensor 46 Stopping Continuing the dispensing process 46 Configuration and monitoring Function menu settings 47 ERBE DICH een 47 Label stop position 005 47 Dispensing speed 0 0 ce eee 48 Suppressing start signals 48 Label position on the product 49 4 2 2 4 3 4 3 1 4 3 2 4 3 3 4 3 4 9 1 9 1 1 5 1 2 6 1 6 1 1 6 1 2 6 1 3 7 7 1 Monitoring functions Material end Roll diameter Missing labels Material tear 0 0 0 0 0c eee Using product profiles Loading a product profile Storing a product profile Selecting the memory location Entering profile names Deleting a p
9. the name using any text you choose Entering profile names Accepting the profile name Product 1 without changing it gt Press the I button twice The profile is saved Display Store prod prof Storing Changing a profile name gt Press the lt gt button Display Store prod prof Prof x _ The underscore marks the active position gt Pressthe orthe button to scroll through the available characters until the character you require appears gt Press the I button to accept the character The underscore jumps to the next character gt Enter the next character in the same way gt When you have entered the last character press the button 4 OPERATION 4 3 USING PRODUCT PROFILES The profile is saved Display Store prod prof Storing The product profile has now been saved 4 3 4 Deleting a product profile gt Call the MACHINE SETUP gt Del prod profil function The memory location that was active last is displayed gt Pressthe f orthe button until you retrieve the memory location you require 1 16 gt Press the button to delete the memory location Display Del prod profil Clearing The product profile has now been deleted 9 FTER OPERATION 5 1 MAINTENANCE AND CLEANING 5 1 1 Cleaning agents amp Cleaning agents for rubber rollers Roller cleaner order number 98925 If other
10. 600 mm Realtime clock none Label roll Control panel graphical display with Winding direction inner or outer Wee DNS Ze nes Unwinder outer up to 400 mm Rewinder outer up to 270 mm Core inner 38 1 76 2 101 6mm 1 5 3 4 2 Material passage width Width of Label Liner Depending on the dispensing edge width N 5 buttons 2 1 OVERVIEW Interfaces Sensor interfaces for external sensors Label sensor Alternative label sensor Product sensor APSF sensor Rotary encoder External OD control sensor Internal sensor inter faces Material unwinder Pressure roller Dancer arm PLC interface Outputs Inputs Data interfaces Serial Ethernet USB CF card Control panel interface plug in each case 4 pin M12 Wenglor OPT242 P800 optical NPN 24 V con trollable sensitivity PNP NPN 24 V PNP NPN 24 V single phase two phase PNP P P 24 V max 20 kHz PNP 24V Light barrier not used bi phase light barrier en coder D Sub15 optically insu lated optionally via two 8 pin M12 separate in puts outputs in each case 4x PNP 24 V a maxi mum of 500 mA channel total permissible output current 1500 mA 3x PNP NPN 24 V RS232C D Sub 9 max 115200 Baud 10 100 BaseT RJ45 Device V1 1 USB B Full soeed operating mode 12 MBit s Slot for 1 CompactFlash card RS 485 Mini DIN 6 con nection for remote co
11. 7 1 EC DECLARATION OF CONFORMITY herewith assert that we have designed and built the device described in the following to conform with the basic safety and health requirements of the relevant EU directives Name of the devices Device type Serial number Relevant EU directives Other applicable harmonised norms in particular Year of first CE marking Eching 27 October 2008 ALS 306 ALS 309 Label dispenser Consists of a sequential number five digit date code YYMM ending device name ALS306 or ALS309 Example 04006081 0 ALS306 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive EN 60 950 1 A11 2004 Information technology equipment safety EN 55 022 2006 class A A1 2007 Information technology equipment Radio disturbance characteristics Limits and methods of measurement EN 61000 6 2 2005 Immunity standard for industrial environments EN 61 000 3 2 2006 prA2 2007 Limits for harmonic current emissions EN 61 000 3 3 1995 A1 2001 A2 2005 Limitation of voltage changes voltage fluctuations and flicker Anl he Markus Roderer General Manager 2008 051790 Avery Dennison Deutschland GmbH Ohmstra e 3 85386 Eching Germany AVERY Telephone 49 8165 925 0 DENNISON http www machines averydennison com Link information to your product
12. label from the applicator gt Press the f button Changing the counter reading gt Set the counter reading using the ispei unter function Starting the unit in configuration mode To start the unit in configuration mode gt Set ES e to Offline Counting labels backwards To count dispensed labels backwards from a starting value to zero gt Set LABEL SETUP gt Stop count mode to Enabled gt Use the LAB Label stop quan function to define the starting value se STATUS Online Labels 22 Control panel in dispensing mode 292 labels dispensed A Explanation of buttons in dispensing mode 2 PRODUCT DESCRIPTION 2 3 OPERATING MODES Online settings The machine is in dispensing mode To switch to the online settings mode gt Press the lt gt button The display shows the dispensing speed 23A and the start offset 23C The button assignments are as shown on the buttons You can increase button or lower button both settings in the dispensing mode 23D Dispensing speed Setting range 5 0 60 0 m min Display fix The dispensing speed is constant Display var The dispensing speed automatically adjusts to the speed of the conveyor belt speed adaption Start offset Setting range 0 0 999 9 mm The start offset indicates the distance between the product sensor and the dispensing edge D
13. mode you have access to several menus providing a fixed sequence of functions that can be carried out You can set the unit so that some ofthe menus are not shown Figure 24 shows the button functions for switching between the individual menus and for leaving them mse OFFLINE l a t B LABEL SETUP DLIA MACHINE ul Ss DITA INTERFACE PARA KA DILIG O KO A C pita APPLICATOR PARA DID e SERVICE DAGNOS p DITA amp SERVICE DATA 24 Menu selection and button functions in configuration mode A Button for triggering a dispensing procedure and for starting the measurement of lengths B Explanation of buttons in configuration mode C Menus 2 PRODUCT DESCRIPTION 2 3 OPERATING MODES Functions Every submenu contains functions for setting the unit controls Figure 25 shows the button functions for changing settings using the MACHINE SETUP gt Language function as an example ac MACHINE SETUP Store Prod Prof nic MACHINE SETUP Language ac Language English DTe Language German 25 Button functions for setting the MACHINE SETUP gt Language function A Button to Accept changes B Button to Cancel changes ALS 2 4 FUNCTION DESCRIPTIONS 2 4 1 Overview of functions SET Load prod profil Dispenser type Light sens type gt EASYPLUGINTERPR Port address Gap detect mode Store prod prof Labelsen InType Interface Ethernet speed
14. quired safeguards gt Only configure the unit in accordance with this manual and with the required care gt Only use original accessories gt Do not make any modifications or altera tions to the unit gt Repairs to the device may only be per formed by authorised specialists who are aware of the risks involved Protection against injuries by electrical current WARNING The machine operates using mains voltage Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns gt Only operate the unit once the housing has been reassembled properly gt The machine may only be connected by authorised specialists who are aware of the risks involved gt Before cleaning switch off the unit and remove the power cable from the socket ALS gt Only link the unit to devices that fulfil the SELV safety extra low voltage circuit re quirements specified in EN 60950 gt Make sure that the power switch at the machine is accessible gt In case of emergency switch off the de vice WARNING The unit is not protected against splashing water in its standard model gt Keep the unit dry gt If liquids have penetrated the unit switch it off and disconnect or unplug the power cable immediately Inform a service tech nician CAUTION A too high or low supply voltage can damage the unit gt Only operate the device using the system voltage indicated on the name
15. the buttons depend on the operating status of the device these functions are explained in the section Operating modes on page 26 Language The display language can be selected from a choice of 7 languages Default setting is English For selecting another language see chapter Functions on page 29 A 2 PRODUCT DESCRIPTION 2 1 OVERVIEW 2 1 3 Connection arrangement Connections on the rear side of the device A Label sensor Product start sensor Rotary encoder for automatic speed adaption Alternative label sensor mo DW Roll diameter sensor for external OD control on unwinder 1 or 2 Signal inputs optional Signal outputs optional Io 7 not applied OD sensor 1 for internal OD control on unwin der 1 OD sensor 1 N Cc OD sensor 2 for internal OD control on unwin der 2 OD sensor 2 PLC signal interface USB device interface Plug in card slot CompactFlash cards Connection for external control panel RS485 Serial interface RS232 Network connection Ethernet 10 100 Optional Applicator Interface Al TE 4 Connections on the machine rear side 11a Ip VO 2 TFT Power supply connection ea For information on connecting the unit see 1 chapter Power supply connection on page 34 For information on connecting the sensors see chapter Connecting sensors on page 35 1 OD Outer Dia
16. A of the unit to I On The following messages are displayed during the start process ALS306 RH V 1 34 machine type and firmware version ONLINE Label 0 Once switched on the ALS 30x is in dispensing mode see section Dispensing mode on page 26 4 1 2 Starting label dispensing Dispensing with a product sensor Once switched on the ALS 30x is in dispensing mode this means that triggering the product sensor will cause a label to be dispensed Prerequisites The label length must be specified The product sensor must be connected P N The sensors must be configured correctly N PNP NPN Dispensing without a product sensor lt is also possible to trigger the dispensing process without a product sensor The machine is in dispensing mode gt Press the button The machine is in configuration mode gt Press the button briefly less than two seconds 4 1 3 Stopping Continuing the dispensing process The machine is in dispensing mode Stopping the dispensing gt Press the button The dispenser stops One of the two texts appears ONLINE Stopped press NW key to start or ONLINE Stopped remove label press key to start 1 Second line scroll text Continuing the dispensing gt Ifthe lower text is displayed Remove the label from the applicator gt Press the f button 4 OPERATION 4 2 CONFIGURATION AND MONITORING
17. Dispense speed Del prod profil Startsen In Typ Spooler mode MAC Address Slew speed Dispense counter Start disp mode Dispenser ID no SNMP Agent Label pitch Turn on mode Start error stop Spooler size SNMP Password Lab stop offset Language On inhibit enter Offline mode FTP server Start offset Access authoriz On inhibit leave Interface delay FTP Password Product length Default values Apply key MEI WEB server Multi label mode Factory settings Material end err gt COM1 PORT WEB display refr Label 2 offset Store parameters Material end warn Baud rate WEB admin passw Label 3 offset Auto Sensor Adi OD Sensor mode No of data bits WEB supervisor p 7 Miss label tol Sensor Adjust OD Sens polarity Parity Time client Miss label mode Speed Adaption Stop bits Time server IP 8 Stop count mode Encoder Type Data synch Sync interval Frame error DHCP host name gt NETWORK PARAM N IP address et mask pF ateway adress Label stop quan Encoder Resol Encoder Diameter Rew operation Tandem Operation Tandem Synch Slave IP address Tandem Distance 26 Functions menu part 1 grey shading function is described in the following 1 Only appears if LABEL SETUP gt Multi label mode 2 labels start oder 3 labels start 2 Only appears if LABEL SETUP gt Stop count mode Enabled 3 Only appears if MACHINE SETUP gt
18. Dispense speed function The speed at which the label is dispensed Setting range ALS 306 5 0 60 0 m min default 10 0 ALS 309 5 0 45 0 m min default 10 0 See chap Dispensing speed on page 48 Slew speed function Feed speed during initialisation Setting range ALS 306 5 0 60 0 m min default 1 0 ALS 309 5 0 45 0 m min default 1 0 Label pitch function Label pitch label length space Setting range 5 0 600 0 mm See chap Label pitch on page 47 Lab stop offset function Stop position of the label on the dispensing plate Setting range 0 0 999 9 mm default 20 0 See chap Label stop position on page 47 Start offset function Distance between the product sensor and the top of the dispensing plate Setting range 15 0 2999 9 mm default 15 0 See chap Label position on the product on page 49 Product length function With this function activated the machine ignores all start signals until the product has passed the dis pensing edge Setting range 0 0 1999 9 mm default 0 0 See chap Suppressing start signals on page 48 Multi label mode function Settings Disabled 2 labels start 3 labels start Disabled Each start signal causes printing of one label 2 labels start Each start signal causes printing of 2 labels 3 labels start Each st
19. FORE OPERATION 3 3 MECHANICAL SETTINGS 3 3 3 Positioning the label sensor gt Release the thumb screw gt Position the sensor along the axle in such a way as to allow it to register the spaces between the labels oe The LED 53A lights up when the sensor is 1 positioned over a label 3 3 4 Setting the dancer arm restoring force The unwinder dancer arm is preset in a way that a wide range of label materials can be processed whithout ha ving to change the dancer arms restoring force Even so very narrow label material can under certain circumstances tear off or expand in a way which results in poor labelling precision In those cases the restoring force must be decreased gt Loosen the lock ring 55B To do so hold the adjustment ring 55A and turn the lock ring opposite the direction indicated by the pictured arrow gt Turn the adjustment ring 55A in arrow direction 55 arrow to increase the restoring force Turn the adjustment ring 55A against arrow direction 55 arrow to decrease the restoring force gt Retighten the lock ring against the adjustment ring A service technician can restore the factory set Experts ting see service manual chap 6 2 3 section Adjusting restoring force of dancer arm 55 A Adjustment ring B Lock ring 4 OPERATION 4 1 START UP AND SHUTDOWN 4 1 1 Turning on the unit 56 Main switch A of the ALS 30x gt Set the main switch 56
20. N 2 2 OPTIONS Splice unit The splice unit is an accessory for ALS 30x labellers which are operated with two lateral unwinders The unit makes it easier to bond start and end of the two label webs Thus the label web doesn t have to be newly fed in 16 Splice unit A Dust Splash guard Additional sealing of the electrical connections and of the housing fulfils the requirements of the IP 54 protec tion class 17 Outer diameter control sensor The outer diameter control sensor OD sensor triggers a warning if the label roll outer diameter falls below a certain adjustable value 18 OD sensor A 23 2 PRODUCT DESCRIPTION 2 2 OPTIONS Cable kit for internal outer diameter control Those cables are required to connect the sensors which are integrated in the unwinder to the control unit of the ALS 30x If connected the internal OD control can be used For 2 unwinders 2 cable kits are required Additional material guide disk The additional material guide disk 20A improves the lateral guiding of the material roll This option is espe cially recommended if very narrow material lt 30mm width is processed Capacitive label sensor Optional sensor required for processing transparent labels 21 The sensor is mounted to the rods of the dis pensing edge holder 19 Cable kit for internal outer diameter control 21 Capacitive label sensor with bracket and cable
21. Swivel the dancer arm of the righthand side unwin der downwards until the brake releases and keep it there gt Turn the unwinder until the label web is thightened Release the dancer arm e tis recommended to check the material rewin 1 der each time the roll is changed This avoids additional production stops for clearing the re 49 Material ends bonded with adhesive tape winder 3 BEFORE OPERATION 3 3 MECHANICAL SETTINGS 3 3 1 Adjusting the unwinder s core diameter Tool Pi 3mm hexagon Allen screwdriver The unwinder can be adjusted with core adapters 50A to fit the inner diameter of the label roll The adapters must be fitted and dismantled in different ways depending on this diameter 38 1mm 1 core gt Unscrew the screws 50B 2 for each adapter and remove the adapters 76 2 mm 3 core gt Screw on the adapters as is shown in Figure 50 101 6 mm 4 core gt Screw on the adapters as is shown in Figure 51 3 3 2 Positioning the pressure roller gt Open the pressure roller 52B To do so rotate the lever 52C until the roller snaps up gt Release thumb screw 52A gt Align the pressure roller over the backing paper so that it is centred gt Close the pressure roller gt Screw the thumb screw tight 51 Core adapter positions for a core diameter of 101 6 mm 52 Setting the position of the pressure roller B 3 BE
22. ameter 205 mm for the rewinder roll has been reached end of a new label roll was glued gt Remove the rewound backing paper gt Press the I key to confirm the error message ALS 6 1 STATUS MESSAGES Status Status text Cause Action to take 5147 Tandemsynch Init This message can only appear gt Check if the slave machine had 1 during tandem operation been switched on before the master machine if not repeat the switching a on in the correct order first slave Communication between the master and slave machines is not men asien l functioning gt Check if both machines are connected with the tandem interface cable if not connect them For detailed information contact a service technician 5152 Winding direct The backing paper end is not correctly Attach the backing paper web to the attached to the rewinder mandrel rewinding mandrel as described in chap Threading the label web to the rewinder auf Seite 42 gt 5200 Home position oe This message may appear when 1 operating the applicator The applicator did not reach its home position upper end position within the intended time frame Applicator operation set but no gt Set applicator available to PLC interface The applicator is stuck gt Remove any obstructions Compressed air applicator gt Check compressed air connection Compressed air supply interrupted or and reconnect correctly if
23. art signal causes printing of 3 labels 2 4 FUNCTION DESCRIPTIONS Label 2 offset function Defines the distance of the 2nd label for the function see above The distance is measured from the front label edge of the preceding label Setting range x 9999 9 mm Default x with X Label 3 offset function Defines the distance of the 3rd label for the function see above The distance is measured from the front label edge of the preceding label Setting range x 9999 9 mm Default x with X Miss label tol function Missing label tolerance The maximum permissible number of successive missing labels on the label strip Setting range 0 10 mm default 1 See chap Missing labels on page 51 Stop count mode function Settings enabled disabled Enabled Dispenser counter counts backwards starting with the value that has been set using the function When the counter reaches zero no further labels are dispensed Disabled The dispenser counter counts forwards which means that the dispenser counter is incremented with each label that is dispensed Label stop quan function After this amount of dispensed labels the dispenser stops Function only appears if enabled Setting range 0 99999 default 0 33 ALS 2 4 4 MACHINE SETUP menu Store prod prof function Storing a product profile see chap Storing a prod uct profile on page 52 De
24. cleaning agents are used there is a chance the rubber may corrode Cleaning agents for metal deflection rollers Cleaning solvent alcohol based solvent isopropyl alcohol spray for removing labels Cleaning the unit s housing Commercially available neutral cleaning liquid WARNING Cleaning solvent alcohol based solvent and isopropyl alcohol are highly inflammable gt Keep the cleaning agents as well as any used cleaning cloths away from open flames and other sources of ignition gt Do not smoke gt Observe the safety instructions on the container CAUTION Unsuitable cleaning agents can cause considerable damage to the unit gt Do not use any cleaning agent that could damage or destroy the resin surface labelling display nameplates electrical components etc Observe the instructions of the cleaning agent manufacturer gt Do not use any abrasive or plastic corroding cleaning agents gt Do not use any acidic or alkaline solutions 5 AFTER OPERATION 5 1 MAINTENANCE AND CLEANING 5 1 2 Regular maintenance The label dispenser is designed to be maintenance free However you should service the unit regularly in order to ensure reliable long term operating results Removing paper debris Depending on operating conditions you should perform the following at least once a week gt Wipe the paper residue from the rollers and edges gt Clean the sensor lenses with a soft b
25. e me en GE NISOR paa i gt LJ ER j Lis e aL The ALS30x Label Dispenser is ready for operation in its idle mode A Dancer arm B Pressure roller C Dispensing edge D Drive rollers E Rewinder 2 PRODUCT DESCRIPTION 2 1 OVERVIEW 2 1 5 Technical specifications Characteristics Label sensor Dispensing speed Distance to peel edge ALS 306 max 60 m min L shape dispensing ALS 309 max 45 m min edge 19mm Labelling halt precision at Transmission sensor Wenglor OPT242 P800 the peeling edge optical NPN Variable speed lt 1mm Constant speed lt 0 5 mm Power supply Speed control Fixed setting or automatic System voltage speed adaption via the rotary encoder 100 240 V AC at 60 50 Hz power frequen cy permissible tolerance 10 Precision internal OD 3 OD control Current consumption max 5 1 A at 100 V max 2 1 A at 240 V 1 The maximum usable dispensing speed depends on the label geometry Power consumption max 510 VA Labels Fuses Fuses integrated in the FF NEE E E O E power supply Label material Converted self adhesive label material with liner 3 Not accessible for user or service technician Internal rewinding yes Electronics Material passage width 2 ALS 306 up to 160 mm Processor 32 Bit CPU MIPS Core ALS 309 up to 233 mm RAM 16MB Minimum label width 20 mm ROM 4MB Label length 20
26. e operating personnel can use the unit on their own and safely The operating personnel can remedy small operational disruptions on their own gt At least two people must be instructed in the unit s usage gt Enough label material must be provided for testing and instructional purposes Qualifications for configuring The configuration of the controls requires qua ExPeRTS ified expertise Personnel configuring the unit must be acquainted with the functionality of the label dispenser Personnel configuring the unit must be acquainted with the modes of operation within the facility in which the label dispenser is Integrated The personnel configuring the unit must be able to use the additional menus properly and appropriately for specific project requirements 1 2 SAFETY INSTRUCTIONS 1 2 2 Operational safety of the unit Proper usage The label dispenser is a fully automatic unit for atta ching self adhesive labels to products or packaging The company operating the unit must install it with sui table equipment to protect operating personnel from danger for example the danger ofthe hands or fingers being crushed by reaching in between the product and the dispensing edge WARNING Improper usage of the unit can cause accidents property damage and production downtime gt Only use the unit in accordance with the instructions specified in this manual gt Do not operate the unit without the re
27. eed after a label has been dispensed I ih amp TT A Z Z O Dispensing edge Pictured fixed L shape dispensing edge Optional available are swivelling L shape dispensing edge spring loaded L shape dispensing edge pneumatic L shape dispensing edge Pressure mechanism Presses the pressure roller against the drive roller Prevents the backing paper from slipping through Releases automatically once the backing paper has been drawn around the drive roller Mounting flange Dancer arm Controls the rewind speed Release button Pressing this button reduces the diameter of the rewinder core Allows the easy removal of the rewound backing paper Rewinder Rolls up the used backing paper External roll diameter sensor option Generates a warning signal if the critical roll diame ter is reached 2 PRODUCT DESCRIPTION 2 1 OVERVIEW 2 1 2 Control panel A z ON STATUS Operating LED Lights up green when the device is switched on cl Online Labels 292 Error LED D Lights up red when an error occurs LCD display Displays functions configured values operating 3 The ALS 30x control panel in dispensing mode states and error messages a ee What is displayed at any one time depends on the C LCD display operating status of the device these screens are D Buttons explained in the section Operating modes on page 26 Buttons The functions of
28. ence of the operating company and the service technician gt Ensure that the following prerequisites are fulfilled in accordance with the service instructions The machine is installed properly and configured in accordance with the guidelines All required safety mechanisms have been installed The unit has performed at least one successful test run The unit is connected to the power supply gt The users have the required personal protective equipment for example a hairnet Ensure that the protective equipment is utilised correctly Due diligence of the user gt Check that the safety installations are working properly gt Inspect the machinery for any visible damage Report any ascertained defects immediately gt Use the required personal protective equipment correctly for example wear a hairnet gt Remove any unnecessary materials and objects from the operating area of the unit gt Ensure that only authorised persons are within the operating range of the machine gt Ensure that starting up the machine will not injure anyone _ 1 PLEASE NOTE 1 2 SAFETY INSTRUCTIONS 1 2 4 Safety notes on the unit i CAUTION Warning notes on the unit represent important information for the personnel using it gt Do not remove warning notes gt Replace any missing or illegible warnings The Pinch Point warning 1A note warns you of the danger posed by the machine s rota
29. ewound backing paper B Release button C Backing paper path 36 Inserting the material roll 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL 3 2 3 Threading diagrams WW k k leony 37 Threading guide for ALS 30x dotted line roll with labels facing inwards 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL wo Mg Wp 88 Threading guide for ALS 30x with a 45 rotated dispensing edge dotted line roll with labels facing inwards 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL 39 Threading guide for ALS 30x with a 90 rotated dispensing edge dotted line roll with labels facing inwards Foruse with a swivelling angle of 30 or more additional deviation rollers must be installed Long dispensing edge holder 2 rollers 39A B Short dispensing edge holder 1 roller 38A 1 0 Dispensing edge holder shows vertically downwards with the machine mounted in horizontally 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL Threading the label web at the dispensing edge Fixed 40 and swivelling L shape dispensing edges gt Unroll 2 5 m of label web and remove the labels from it gt Pass the backing paper around the first deflection roller 40A and through the slot in the sensor 40B gt Feed the backing paper under the pressure roller 40C to the dispensing plate 40D gt Feed the backing paper around
30. h narrow down the error more precisely ALS Action to take gt Delete the message by pressing the key gt Switch the machine off wait 30 seconds and switch it back on gt Ifthe error message appears repeatedly call in a servicing technician 5001 No gap found Material end if no outer diameter OD control is activated The maximum limit for missing labels was exceeded The machine is not correctly set for the type of label Label length is not correctly set Photoelectric label sensor is dirty Photoelectric label sensor is incorrectly positioned Photoelectric label sensor is not connected correctly Photoelectric label sensor is defective Rotary encoder is not adjusted correctly gt Check the points listed above and correct if necessary gt Press the I key to confirm the error message 5002 Material end Material end if the internal OD control is connected and activated Internal OD control is notconnected but activated gt Insert new label roll gt Deactivate the internal OD control Off 5026 MotorProtect CPU 67 List of error messages Dust filter liner exhausted This leads to overheating the machine There are some more possible causes which require a qualified service technician to cure 57 gt Renew the dust filter liner Let the machine cool down gt Switch the machine off wait 30 seconds and switch it back on gt
31. he 59 A Product length function the machine ignores all start signals until the B Label product has passed the dispensing edge C Product sensor D Product with recesses arrows 48 4 OPERATION Label position on the product Prerequisites The label length must be specified The label stop position must be set Configuration in dispensing mode gt Use the two right buttons to set the start offset see Online settings on page 27 Or use the function menu settings gt Callthe LABEL SETUP gt StartOffsetfunction and set the Start offset The label should be flush with the front edge of the product gt Enter the distance between the product sensor and the dispensing edge 60A The label should be stuck at a distance from the front edge of the product gt Increase the start offset by the distance 61A to the product s front edge 4 2 CONFIGURATION AND MONITORING 60 Distance between the product sensor left and the dispensing edge right 61 Distance A between the label and the product s front 4 2 CONFIGURATION AND MONITORING 4 2 2 Monitoring functions While in dispensing mode an electronic controller monitors the following functions Material end Roll diameter OD outer diameter To enable a quick renewal of the material roll the machine can alarm the operator before the end of the material roll is reached This provides the OD control which is a
32. he dispensing edge ALS 4 2 CONFIGURATION AND MONITORING Dispensing speed You can set the dispensing speed to a fixed value or you can configure itto automatically adjustto the speed of the conveyor belt speed adaption The second option requires you to connect a rotary encoder that measures and relays the conveyor speed to the dispenser Configuring a fixed value gt Use the two left buttons to set the speed in dispensing mode online settings see Online settings on page 27 Or use the function menu settings gt Call the function and set the speed you require Configuring speed adaption gt Turn the function on by setting to Yes gt Set and y q as EXPERTS appropriate for the employed rotary d 4 encoder See the service manual for information on suitable rotary encoders Suppressing start signals A start signal can be prematurely triggered by the shape of the product or reflective surfaces what can cause erroneous labelling In case of a product causing unwanted additional start signals while the product passes the dispensing edge those signals can be suppressed by setting function to the product length C Example 59 lf the product D reaches the product sensor C a start signal is sent and the machine dispenses a label The recesses in the product trigger additional start signals D the product would be labelled several times With the product length A set in t
33. ion Mounting positions IP 54 special equipment side bottom rear Labelling positions top side bottom Holder for L shape dispensing edges Short holder single mounted Pivotable in steps of 15 in a range of 0 to 90 Long holder double mounted Pivotable 0 or 90 L shape dispensing edges Optional Fixed Swivelling Spring loaded Pneumatic 19 to take adequate measures The FCC regulation demands the following information text for class A devices NOTE This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense 2 PRODUCT DESCRIPTION 2 1 OVERVIEW 2 1 6 Design models The ALS 30x can be adapted to client requirements un der several aspects Aspect Adaption Conveyor direction Right handed RH Left handed LH machine Mounting position Hor
34. ion timeout 2 ACTIVE INPUTS gt MEMORY DATA Apply comp time Start signal gt POWERSUPPLYDATA Ram memory size Inhibit signal Type Flash mem size OD sensor signal CompactFlash Default values es Temerne a E gt CPU BOARD DATA 9 Only appears if Interface mode PLC signals CPU identifier 10 Only appears if Interface mode Applic signals 11 Only appears if applicator type PEP PEP Blow on Reverse PEP BTS or PCB Revision f LA TO timed 12 Does not appear if applicator type LTP LTPV PEP Direct dispense or LA TO FPGAversion f 13 Does not appear if applicator type ASA Direct dispense or LA BO MAC Address 14 Only appears with Al board installed and if Interface mode Applic signals 15 Only appears with Al board installed and if Interface mode PLC signals 16 Only appears with Al board installed Serial number 17 Only appears if remote display is connected 18 Only with plugged in CF card Production date PCB part number Board part numb 27 Functions menu part 2 31 2 4 FUNCTION DESCRIPTIONS 2 4 2 Notes Function descriptions The following chapters only describe those functions that are necessary for operating an ALS 30x that has been configured and set up These functions are highlighted in grey in the overview Settings of functions that are not described in the foll
35. ispensing manually To manually trigger the dispensing of individual labels gt Press the button Dispensing speed As specified in the setting see above To switch back to dispensing mode gt Press the buttons A B C ON far Speed Offset 12 2 fix 0 0 J a tl NJ E F G H 23 Control panel in the online settings mode A Dispensing speed display here 12 2 m min constant B Dispense label button C Start offset display here 0 mm D Explanation of buttons in online settings mode E Button to lower dispensing speed F Button to increase dispensing speed G Button to lower start offset H Button to increase start offset 2 PRODUCT DESCRIPTION 2 3 OPERATING MODES 2 3 2 Configuration mode The machine is in dispensing mode Switching to configuration mode gt Press the button twice Display OFFLINE gt Press the lt gt button Display LABEL SETUP LABEL SETUP is the name of the first menu that is currently active In configuration mode the button assignments are as shown below the buttons Function of the double arrow button To dispense individual labels gt Press the button briefly less than two seconds Dispensing speed As specified in the configuration Speed Adaption is not active To automatically calibrate the label length gt Hold down the button for a while longer than two seconds Menus In configuration
36. izontal vertical of the machine Top side labelling Mounting point at Top bottom right left rear the machine side Unwinder amount 1 2 Unwinder moun Top right left ting point Side right left oe The label dispenser operation described in this 1 manual is based on the right handed version with the features pictured in 6 Other versions are only taken into account if the explanations 6 ALS30X RH with the following features or figures of the designs differ significantly Conveyor direction from left to right Mounting position horizontal top labelling Unwinder amount 1 Unwinder mounting point top left 7 ALS 30X LH with the following features Conveyor direction from right to left Mounting position horizontal top labelling Unwinder amount 2 Unwinder mounting point lateral left and right 8 ALS 30X RH with the following features Conveyor direction from left to right Mounting position vertical side labelling Unwinder amount 1 Unwinder mounting point top right 2 PRODUCT DESCRIPTION 2 2 OPTIONS External control panel An external control panel can be connected in addition to the integrated control panel An external control panel is useful if the standard control panel is difficult to access due to the position in which the unit is installed 9 External contr
37. l prod profile function Deleting a product profile see chap Deleting a product profile on page 53 Start error stop function Determines how the machine responds in the event of a product start error A product start error occurs when a new start signal arrives before the current dispensing cycle has ended Settings On Off On Start errors are issued If a start error occurs the device stops and displays a relevant error message Off Start errors are ignored Turn on mode function The operating mode of the unit after it is turned on Settings Online Offline Online Dispensing mode Offline Configuration mode Language function Language of the displayed text Settings English French German Spanish Ital ian Dutch Danish Polish Turkish Material end err function Refers to the internal OD control Settings On Off On Material end triggers a status message Off Material end triggers no status message Precondition The two sensors at each of the un winders are connected to the machine see chap chap Connecting sensors on page 35 Material end warn function Refers to the internal OD control Defines the critical roll diameter Adjustment range 50 500 mm Default setting 80mm 3 BEFORE OPERATION 3 1 ELECTRICAL CONNECTIONS 3 1 1 Power supply connection WARNING This machine operates using mains voltage Touching live electrical
38. ls and objects from the operating area of the unit gt Make sure that only authorised persons are within the operating range of the machine gt Use the required personal protective equipment correctly forexample wear a hairnet safety glasses 34 Main switch A on the housing 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL 3 2 2 Inserting a label roll WARNING Risk of injury due to moving and rapidly rotating parts gt Before inserting the label roll ensure that the device is turned off at the main switch gt Do not under any circumstances turn the device on before the label web is threaded in completely Removing spent backing paper Assuming backing paper has gathered on the rewinder 354 gt Press the release button 35B The tensioning mechanism of the rewinder is slackened gt Remove the rewound backing paper Removing glue residue gt If necessary clean the following components Dispensing plate Deflection rollers Drive rollers Pressure roller gt Follow the directions provided in section Maintenance and cleaning on page 54 Inserting a new label roll gt Push the material roll 36A onto the unwinder as far as it will go gt Rotate the rotary knob 36B in a clockwise direction until the label roll sits tightly gt Run the label web around the deflection roller and the dancer arm roller 36C as shown in the figure 35 A R
39. meter ih Ol 2 PRODUCT DESCRIPTION 2 1 OVERVIEW 2 1 4 Mode of operation In labelling mode the label web is first pulled from the label roll around the dancer arm 5A which consistent ly maintains even tension in the label web The feed rollers 5D in front of and behind the dispensing edge 5C draw the label web across the dispensing plate The label is peeled from the backing paper on the dispensing plate and is pressed onto the product by the pressure roller 5B The feed roller drives the label web forwards the length of one label and stops until the next product arrives at the dispensing plate The feed is started by the product sensor mounted on the conveyor belt The stop control provided by the label sensor on the dispensing edge ensures the feed is halted as soon as a gap Is detected between two labels The spent backing paper runs from the dispensing edge around the drive roller 5D to the rewinder 5E The dancer arm regulates the rewinding speed The entire operation of the label dispenser is controlled and monitored electronically If errors occur the device controls output an appropriate notification for the oper ator If necessary the labelling operating mode is halt ed automatically An electronic signal is output at the same time The signal can be fed to an external control ler and evaluated _ i W FAN m as 7 ut rer ta PERAN P k er i Fie WER ANET i _ ng Sate an S
40. n to delete the message gt Switch the device off wait 30 seconds and then switch it on again If the error reoccurs gt Request a service technician Error messages that are not mentioned here Experts are described in the service manual Warnings Warnings indicate less severe status than error messages The labelling is not interrupted by a warning Warning format ONLINE Materialend warn 66 Example of a warning Materialend warn Warning text a short description of what has caused the warning Setting back a warning gt Press the I key works earliest with firmware versions gt 1 10 ALS 6 1 2 List of warnings Displayed text Produktstartwarn Meaning New start signal during the dispensing operation Or Several missing labels on the web which can not be compensated APSF speed warn Theconveyor speed exceeded the max speed of the dispenser OD Sensorwarning Material low External OD control Critical material roll diameter is reached Internal OD control Critical material roll diameter is reached Toomany products 56 Too many products between sensor and dispensing edge max 8 products are allowed 6 1 STATUS MESSAGES 6 1 3 List of error messages Status Status text 5000 Bus device Cause Device at I C Bus cannot be contacted In most cases this message appears as the first in a series of two or three messages whic
41. n trol ALS Internal Interfaces RFID Connection for RFID read write unit special equipement Applicator Interface Connection for Applicator Interface Al board spe cial equipement 4 Not yet available Status messages test functions product profiles Automatic halt if the label roll is spent or no gap was found the max admissible number of missing labels is reached Test functions Automatic diagnostics check when switched on Output of system data via data interface Label counter Operating hours counter Status indicators Storage locations for up to 16 product profiles Dimensions Width x height x depth ALS 306 726 x 389 x 386 mm 9 726 x 802 x 386 mm ALS 309 726 x 389 x 470 mm 9 726 x 802 x 470 mm Weight ALS 306 54 kg ALS 309 56 kg 5 Measurements without the dispensing edge bracket and dispensing edge 6 without unwinder 7 with unwinder on top side 18 ALS 2 1 OVERVIEW Certificates CE TUV GS FCC CCC GOST NRTL US CA The regulation DIN EN 55022 demands for class A Environmental conditions Operating temperature 5 to 40 C iel a g 89 1NON CON devices the following text to be printed in the densing manual nn ei pace WARNING This is a class A product Ina domestic ARa ANEEL environment this product may cause radio Protection class IP 21 interference in which case the user may be required Integrat
42. nd backing paper gt Insert a new material roll see Inserting a label roll on page 37 Missing labels A label missing from the label roll does not normally affect the dispensing operation because the label feed continues until a label s edge passes under the label sensor Nonetheless it can be important that missing labels are reported By configuring the function LABEL SET Miss ade tol you can specify whether an error message is triggered after one or several missing labels UP gt Material tear lf the material path tears one of these two messages appears Status num 5002 Material end Status num 5140 Rewinder control Which message appears depends on where the material path is torn The machine stops gt Press the 1 button O1 4 3 USING PRODUCT PROFILES 4 3 1 What are product profiles Product profiles are memory locations that can store all the settings for the machine controls For recurring production jobs they allow you to quickly set the machine to the respective product Number of memory locations 16 The memory locations are numbered In addition you can also enter a text identifier for each memory location with a maximum of 9 alphanumeric characters 4 3 2 Loading a product profile CAUTION Incorrect settings may lead to production problems and damage both the unit and the experts eQuipment gt Only staff who are qualified a
43. nd specially trained should set up product databases gt Call the function The following message appears when no memory location is occupied Load prod profil No setup avail Only occupied memory locations are displayed When memory locations are occupied the memory location that was loaded last is displayed first Load prod profil Prof 1 xxxxxx Above example The profile with the xxxxxx text identifier has been stored at the first memory location Press the forthe button until the profile you require appears Press the 41 button to load the profile The unit restarts afterwards Display after the restart Prof 1 xxxxxx Label 0 in dispensing mode ONLINE is replaced by the current profile name 52 ALS 4 3 3 Storing a product profile Selecting the memory location gt Call the function Display shown when all memory locations are unoccupied Store prod prof Prof 1 Product 1 When memory locations are already occupied the memory location that was last active is displayed Store prod prof Prof 5 customer_xyz A occurring after the memory location number indicates that the memory location is already occupied here by the customer_xyz profile gt Pressthe f orthe button until you retrieve the memory location you require 1 16 gt Press the 1 button to activate the memory location The profile name flashes and you can now replace
44. necessary switched off Cable not correctly connected gt Check cable and connect correctly if 5201 Touch Down The applicator lower end position ne Touch Down was not reached in time 6002 New prog vers New firmware has been loaded Thisisa Press the Online button to confirm message from the labeller that new All parameters are reset to their firmware is available factory settings 6030 New Parameters New firmware was loaded with the result Press the Online button to confirm that new functions have been added to Automatic reset is performed the menu All parameters are reset to their factory settings 6207 No file card No compact flash card was found gt Check whether a compact flash card is connected If the compact flash card was not connected until after the machine was switched on Switch the machine off and back on again 67 List of error messages 59 6 OPERATIONAL FAILURES 6 1 STATUS MESSAGES Status Status text 9022 No network link 67 List of error messages Cause Action to take This status message can only appear gt Check whether the network when Ethernet address assignment is connector is plugged in correctly set to DHCP INTERFACE PARA gt correct if necessary NETWORK PARAM gt IP Addressassign The cause is almost invariably an incorrectly plugged in network connector T APPENDIX We Avery Dennison Deutschland GmbH Ohmstrasse 3 85386 Eching Germany
45. ntrol Additional material guide disk Capacitive label sensor PINOT ex ees eee den Hone dice ae eh ee ee ADDICAOl oud deena twee eens ewes Applicator interface Operating modes Dispensing mode 2 222220 Stopping Continuing the dispensing Changing the counter reading Starting the unit in configuration mode Counting labels backwards Online settingS 0000 00 ee Configuration mode Function of the double arrow button MENUS lt i lt 0x0xced oo Krane hear FUNCIONS osre srece tw ta etendew ye See we Function descriptions Overview of functions Notes 0 cee eee Function descriptions Quick setting 2 2 22 LABEL SETUP menu MACHINE SETUP menu ALS 3 1 3 1 1 3 1 2 3 2 3 2 1 3 2 2 3 3 3 3 1 3 3 2 3 3 3 3 3 4 4 1 4 1 1 4 1 2 4 2 4 2 1 Before operation Electrical connections Power supply connection 34 Connecting the power cable 34 Disconnecting the power cable 34 Connecting sensors 20005 35 Inserting label material Prerequisites 0 eee 36 Inserting a label roll 37 Removing spent backing paper 37 Removing glue residue 5 37 Inserting a new label roll 37
46. o modify information in this document No commitment will be made to expand these modifications to include any units delivered earlier Copyright Avery Dennison holds all rights to this manual and its appendices Reproduction reprinting or any other types of duplication even of portions of this manual may only be carried out with express written consent Third persons in particular competitors should not be given access to the information in this manual Printed in Germany Manufacturer Avery Dennison Deutschland GmbH Ohmstrasse 3 85386 Eching Germany Phone 49 8165 925 0 Fax 49 8165 925 231 http www machines averydennison com 1 1 GENERAL NOTES 1 1 2 Illustrations and descriptions Signs and symbols Various information types are indicated in different ways within the document in order to simplify readability and comprehension Sentences starting with an arrow are instructions and guidelines gt Perform the instructions one after another in the specified order The following information begins with a dash Lists Mode descriptions Descriptions of prior steps Prerequisites for following actions Dangers and risk notes Important directions that you must absolutely observe are particularly emphasized WARNING A warning refers to risks that can lead to serious injury or death The warning contains safety measures to protect the relevant persons Always follow the instructions
47. ol panel Fixed dispensing edge The dispensing edge has a fixed connection to the brackets To adjust the vertical position lift lower the entire device The slope angle can be adjusted by rotating the brackets see the service manual for further details Swivelling dispensing edge The position of the dispensing edge can be adjusted vertically The device need not be moved to adjust the position of the dispensing edge the device s mounting need not be dismantled Spring loaded dispensing edge The dispensing edge is pivoted A torsion spring in the dispensing head presses the dispensing edge downwards and onto the surface of the product Allows compensation for height differences between the products or on the product surface 12 Spring loaded dispensing edge mu 2 PRODUCT DESCRIPTION 2 2 OPTIONS Pneumatic dispensing edge The dispensing edge is pivoted in the dispensing head Compressed air presses the dispensing edge onto the surface of the product Allows compensation for height differences between the products or on the product surface Euro dispensing edge holder Enables a vertical fine adjustment of the dispensing edge towards the product without moving the machine Adjustable head joint Enables a single person to fine adjust the declination of the labeller by an angle of 4 14 Adjustable Euro dispensing edge holder 2 PRODUCT DESCRIPTIO
48. owing may only be changed by qualified service technicians These functions are described in the service manual EXPERTS The settings range or the individual settings for a function are shown in square brackets The default value is italicised for functions that have individual settings Settings that consist of several words are shown in quotation marks Bee Quick setting Buttons Effect lt 1 Decrease value with 10fold speed t lt 1 Increase value with 10fold speed 7 Reset value to lowest setting 28 Button combinations for quick setting of functions with a huge value range 2 4 3 LABEL SETUP menu Load prod profil function Loads product profiles from the internal database Product profiles contain product specific settings You can select a maximum of 16 product profiles You can only select product profile numbers that have profiles already stored for them see chap Loading a product profile on page 52 Gap detect mode function After one of the following events the printer must al ways search for the punch that is initialize the label material after switching the device on after changing the label material Settings Manual Autom Forward 32 ALS Manual The operator has to initialize the material always manually by pressing the feed key several times Autom Forward The material initialization is always done automatically if necessary
49. parts may expose you to hazardous electrical currents and may lead to burns gt Make sure that the machine is switched off before you connect the power cable gt The mains connection of the machine may only be done by authorised specialists who are aware of the risks involved gt The power cable should not be more than 3 m long gt Only operate the device using the system voltage indicated on the nameplate Connecting the power cable The machine ships with a separate machine side pow er connector y q The power cable must be produced by an Experts authorised specialist who is aware of the risks involved For information about producing the power 1 cable refer to the Service Manual gt Make sure that the power switch 30A is set to O off gt Connect the power cable 30B to the machine gt Close the locking clip 30C Disconnecting the power cable gt Make sure that the power switch 31A is set to O off gt Open the locking clip 31B gt Pull the connector off 31 Locking clip B closed 3 BEFORE OPERATION 3 1 ELECTRICAL CONNECTIONS 3 1 2 Connecting sensors gt Check whether the required sensors are connected before turning on the unit 32 The minimum required sensors Label sensor installation location dispensing edge Product sensor installation location conveyor belt Additional optional sensors Rotary encoder requi
50. plate gt Ensure that the mains voltage set on the unit is the same voltage as that provided by the electricity supplier 1 2 SAFETY INSTRUCTIONS Protection against injuries by mechanical action WARNING Risk of injury due to moving and rapidly rotating parts Long hair loose jewellery long sleeves and so on are not permissible when using the unit gt Sufficient protective clothing must be worn gt Keep moving parts free from obstruc tions even when the unit is not switched on if there is a chance the machine might be turned on gt Switch off the machine before making any mechanical settings gt Do not wear ties loose clothing jewel lery wrist watches or similar items on your person when near the operating unit WARNING There is a risk that you may get your fingers or hands crushed on the dispensing edge by products on the conveyor belt gt Never reach between the product and the dispensing edge while the unit is in oper ation or ready for operation gt Never reach behind the safety guard or remove it while the unit is in operation Protection against injuries by chemicals N CAUTION Operating materials such as cleaning agents or the solvents in glues can be damaging to health gt Always follow the instructions use and safety regulations specified by the manu facturer ALS 1 PLEASE NOTE 1 2 SAFETY INSTRUCTIONS 1 2 3 Before beginning production Due dilig
51. red for speed adaption External roll diameter sensor provides advance warning of the end of a label roll Alternative label sensor for example capacitive sensor used to detect transparent labels Sensors for internal OD control Requires cabel kit A9767 For two unwinders two cable kits are required gt Connect 2 cables for each unwinder to the unwinder 33A and to the rear side 32F I of the machine oe You can find further information regarding suit able sensor types pin assignments and so on in the service manual GO Paras f W i i A RAR TAR Pye a pat ed d X Lary Str p f LT AM ar fe d ify IT gt vr ib Lh eg Coe G H j E q 32 Sensor connectors A Label sensor B Product sensor C Optional Rotary encoder D Optional Alternative label sensor E Optional External roll diameter RD sensor F Internal OD control at unwinder 1 G Internal OD control at unwinder 1 H Internal OD control at unwinder 2 I Internal OD control at unwinder 2 33 Connectors A for internal OD control at the unwinder 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL 3 2 1 Prerequisites The label dispenser is turned off at the main switch 34A switch set to O gt Check that the safety installations are working properly gt Inspect the machinery for any visible damage Report any defects immediately gt Remove any unnecessary materia
52. ription Overview Components 000 cece eens 12 Control panel 0000 e eee eee 14 Operating LED 000000005 14 ERO CED ocean eee r a E 14 LCD display n n anaana 14 ButtonS a 32 2 0420 Reber 14 Language 00 cece eee eee 14 Connection arrangement 15 Connections on the rear side of the device 15 Mode of operation 2222222 16 Technical specifications 17 Characteristics ace ch ee eh ahh we 17 BADE S bd ds bre Bs ere BR ere E ed we 17 2 3 2 3 1 2 3 2 2 4 2 4 1 2 4 2 2 4 3 2 4 4 Label sensor 0 000 eee eevee Power supply 0 00000 e eee eee EIBEIFONIES 42 u 2 2 eher dae eae Interfaces ce aaa Be Internal Interfaces 2 2 2222222 Status messages test functions product profiles 222222220 DIMENSIONS mann Environmental conditions Integration 2 222 nn eeeeeeennn Certificates 222mm mn Design models 222222220 Options External control panel Fixed dispensing edge Swivelling dispensing edge Spring loaded dispensing edge Pneumatic dispensing edge Euro dispensing edge holder Adjustable head joint Splice UNIE essre oe bk ew ew ee ee ew oo E Dust Splash guard 00005 Outer diameter control sensor Cable kit for internal outer diameter co
53. roduct liability and warranty claims can only be asserted if the unit was operated in accordance with the directions in the manual gt Before operating the unit read the oper ating instructions and all other notes carefully gt Observe the additional safety and warn ing notes on the label dispenser gt Only permit competent people to operate and configure the label dispenser Keep the product information at hand _ With respect to this manual gt It should be kept at the location where the unit is installed and be available to the operator gt It should always be legible gt Ifthe unit is sold the manual should be made available to the new owner gt The safety and warning notes affixed to the unit itself must be kept clean and legible Missing or damaged signs must be replaced ALS Ensure the required qualifications are met gt Ensure that only trained and authorized personnel operate configure and service the unit gt Only allow qualified and well trained expert personnel or service technicians to perform configurations gt The responsibilities with regard to operation configuration and maintenance should be clearly defined and consistently maintained gt In addition personnel should also be instructed on a regular basis in matters of occupational safety and environmental protection Qualification for operation The instruction of personnel using the unit must ensure that Th
54. roduct profile After operation Maintenance and cleaning Cleaning agentS 05 Regular maintenance Removing paper debris Renewal of the dust filter liner Operational failures Status messages Types of status messages Error M SSageS nummer Warnings 2 Saunen List of warnings List of error messageS Appendix EC declaration of conformity ALS 1 1 GENERAL NOTES ALS 1 1 1 Validity and binding effect of this manual Contents The present manual refers exclusively to the ALS 30x label dispensers It is written for the purpose of ensuring professional usage and calibration of the unit Prerequisites for the use and adjustment are the professional installation and configuration of the unit For any technical questions you may have that are not described in this manual see gt The service manual of the label dispenser or gt Request a technician from one of our sales partners Our sales representatives are available to assist you particularly with configuring the unit as well as in the case of malfunctions Technical status Technical state 12 2009 Software versions 1 34 Avery Dennison reserves the right To make modifications to construction parts components and software as well as to employ comparable components in place of the parts specified in keeping with technical advances T
55. rush or cloth Renewal of the dust filter liner CAUTION 1 An exhausted filter liner can cause the machine to overheat and to break down gt Replace the filter liner at both blowers regularly The replacement interval of the filter liner has to be de fined individually according to dust occurence operating times The filter liner can be cleaned by blowing it out 1 with compressed air or by washing it out In case of overheating the machine the error message 5026 MotorProtect CPU appears see List of error messages on page 57 Pi Tools Screw driver medium size gt Use a screw driver to press the plastic hook upwards 63 arrow gt Replace filter liner 64A by a new or cleaned liner article no A9752 gt Press the filter cover back in place 64 Filter liner A 6 1 STATUS MESSAGES 6 1 1 Types of status messages Error messages When an error occurs the machine stops immediately and displays an error message on the control panel Error messages are displayed as follows Status num 5144 Rewinder init 65 An example of an error message 5144 status number this number makes it easier to identify the message Rewinder init status text a brief description of the error Error messages that are not described here may only be resolved by a qualified service technician When an error occurs that is not described here gt Press the butto
56. the dispensing plate to the second deflection roller 40E Spring loaded 41 and pneumatic 42 L shape dispen sing edges gt Additionally pass the backing paper between the two slim deflection rollers at the joint 41A 42A 40 Path of the label web at the dispensing edge A 1st deflection roller B Label sensor C Pressure roller D Dispensing plate E 2nd deflection roller 42 Path of the label web at the pneumatic dispensing edge option 41 Path of the label web at the spring loaded dispensing edge option 3 BEFORE OPERATION 3 2 INSERTING LABEL MATERIAL Threading the label web onto the drive roller gt Open the pressure roller To do so rotate the lever 43A in a clockwise direction gt Feed the backing paper around the deflection rollers 43B and the drive roller 43C gt Close the pressure roller To do so rotate the lever 44 until it snaps in noticeably 43 Open the pressure roller Se oe eh E AL A i AL me A ABSTD j m m juli y A Threading the label web to the rewinder ma gt Feedthe backing paper around the deflection rollers and the dancer arm as illustrated 45 45 Backing paper threading around deflection rollers and dancer arm 46 Fastening the backing paper to the rewinder gt Clamp the backing paper to the rewinder as shown and tighten it 45 46 gt Manually rotate the rewinder by one turn
57. ting parts they can trap items and draw them in The blue label Read manual 1B demands that users read the unit instructions Pinch point Keep hands clear of rollers Handbuch lesen Read the manual Lisez le manuel Lea el manual Legga il manuale 1 A Left Pinch Point warning Right Position of the warning note on the ALS 30x Item number of the label A5346 B Left Read manual notice Right Position of the notice on the ALS 30x Item number of the label A5331 mu mu 2 PRODUCT DESCRIPTION 2 1 OVERVIEW 2 1 1 Components 2 ALS 306 Label Dispenser right handed version ok N 2 PRODUCT DESCRIPTION 2 1 OVERVIEW Dancer arm Keeps the label material stretched tight evenly Arrests the rotation of the material roll if tension diminishes es Unwinder Spread core mandrel grasps the label roll Core diameter adapter For adjusting the diameter of the dispenser mandrel to match the core diameter of the label roll O Adjusting knob Turning this in a clockwise direction secures the label roll on the unwinder oO Control panel For sending commands to the device and for displaying operating states and error messages An optional external control panel can also be connected to the device 71 Drive roller Drives the label material forwards Pressure roller Prints the label once it is stuck to the product O Label sensor Stops the label f
58. vailable in two versions Internal OD control The machine control elaborates the signals coming from two sensors which are integrated into the material unwinder Before this function can be applied the two sensors must be connected with two external cables accessory to the machine External OD control accessory A light barrier attached to the material unwinder is triggered if the roll OD falls below a certain value Depending on the configuration and setting of the machine different messages appear in case of material end or the roll diameter falling below the critical value ALS Material end Critical OD reached Error message Warning Error message No OD control Status num 5001 none none No gap found Internal OD control Status num 5002 ONLINE none Material end Material low External OD control none ONLINE 2 Status num 5065 OD sensor warn 62 Messages for monitoring label stock 1 If MACHINE SETUP gt Material end err On 2 If MACHINE SETUP gt OD sensor mode Warning 3 If MACHINE SETUP gt OD sensor mode Error If a warning occurs Labelling operation is continued gt Press the 41 button to delete the warning gt Prepare for inserting a new material roll 50 OD material end 4 OPERATION 4 2 CONFIGURATION AND MONITORING lf an error message occurs The machine stops gt Press the 1 button to delete the message gt Remove the rewou
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