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User MANUAL - Avery Dennison

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1. 6 Side labeller left hand version 2 EQUIPMENT DESCRIPTION 2 1 OVERVIEW 2 1 5 Options High speed processing version ALS 380 HS Allows dispensing speeds up to 100 m min Available in all of the above mentioned design ver sions Serial interface Almost all of the setting values can be read out and modified on an external device the machine status can be queried and the machine can be controlled via this interface Roll diameter control Asensor at the unwind unit monitors the diameter of the label roll and along with it the supply of labels The sensor sends a signal when the diameter of the label roll reaches a set value This sensor is required if two labellers are operating in tandem mode see chapter Operation Activation and shut down Tandem operation Adjustable dispensing edge The position of the dispenser head can be adjusted vertically This allows adapting the position of the dispensing edge to changing products The machine does not have to be moved to adjust the dispensing edge The labelling head of the ma chine does not have to be released a Printer Inkjet or heat transfer printer at the dispenser head Applicator If direct labelling from the dispensing edge is not possi ble the labeller can be equipped with an applicator Various kinds of applicators are available depending on the customer s needs 2 EQUIPMENT DESCRIPTION 2
2. 2 Right hand version of the ALS 380 Labeller 2 1 OVERVIEW Unwind unit The unwinding spindle holds the label roll The spreader mechanism chucking wedge se cures the label roll Dancer arm of the unwind unit spring loaded and rotatable O Guiding rod for unwind unit Also secures the label roll Drive roller unit of the unwind unit Pressure roller of the unwind unit m1 moO Braking brush up Allows label ribbon to run smoothly prevents flutter ing Casing Houses the control electronics drive electrical sys tem main switch and fuses Q Mounting brackets For securing the machine in the system Operator panel Braking brush down Dispenser head With integrated label feed Optionally equipped with printer or applicator Dispensing edge The label separates from the backing material here Rewind unit An electrically driven rewinding roller takes up the empty backing material A spreader mechanism secures the backing materi al roll Dancer arm of the rewind unit spring loaded and rotatable Deflection rollers of the rewind unit 11 ALS 2 1 2 Principle of operation In labelling mode the unwind unit 2A and the drive roller unit move the 2D label ribbon A loop is formed in the label ribbon between the pressure roller of the un wind unit 2E and the upper braking brush 2F An ad ditional drive roller unit in the dispenser head 2K pulls the ribbon over
3. 66 CONTENTS 4 4 17 Applicator type APPL 66 5 After operation 4 4 18 EP cylinder dwell time APT1 66 4 4 19 Blowing time APT2 000000 66 5 1 Careandcleaning 73 4 4 20 Delay time APT3 0000 66 5 1 1 Cleaning agents 2 0 0 0 eee 73 4 4 21 Fine tuning of the dwell time APT4 66 5 1 2 Regularmaintenance 73 4 4 22 Delete a product data bank load LOAD 66 REMOVE Papel WASIAT ii setu e niey n Braking brushes 0000 74 4 4 23 Create save product data bank SAVE 66 Capacitive sensor at the dispenser head 75 4 4 24 Delete a product data bank DEL 66 4 5 Automatic dispensing speed 6 Operational malfunctions ANES a eins E E E 67 6 1 Warning messages 76 4 5 1 Electronic transmission ratio of the RPM transmitter EGRA oo a 68 6 1 1 Please observe a nua nuan anaana 76 Setting the compensation factor tnt te Sk oe 68 6 1 2 If a problem OGCCUIS seri Seed Dest a ees he oa 76 Test the setting 20 cease 68 6 1 3 Warning messages 76 4 6 Applicator optional 69 6 2 Errormessages 78 4 6 1 Principle of operation 69 6 2 1 Ifa malfunction occurs 78 4 6 2 Functions in the extended menu 70 6 2 2 Errorcodes 2 200005 78 Please observe the fo
4. 4 OPERATION 4 6 APPLICATOR OPTIONAL Fine tuning of the dwell time APT4 When using an applicator in combination with the auto matic speed adjustment APSF Optimise the accuracy of the label position on the product by fine tuning the dwell time for the applica tor Standard values Blowing applicators approx 25 ms EP applicators 60 ms 100 ms depending on the length of the stroke Prerequisite External RPM transmitter is calibrated EGRA func tion Determining and setting the exact value 74 gt Call up the APT4 function in the extended menu gt Set the setting value for APT4 to 1 gt Allow the conveyor belt with products to run slowly Speed vy 10 m min gt Document the position of the label on the product Value POS in mm 74 Label position in relation to the conveyor belt speed vy low conveyor belt speed POS Label position at lower conveyor belt speed Vy high conveyor belt speed POS Label position at higher conveyor belt speed gt Increase speed of the conveyor belt to approx 25 m min value vp gt Document the position of the label on the product Value POS in mm gt Calculating the setting value for APT4 POS POS 60 APT4 Input the calculated setting value Confirm the value using the ENTER key and exit the function gt gt Test the setting gt Test the labelling accuracy at different co
5. Example 50 The current labelling speed is too high The warning message W__4 appears on the opera tor panel An electronic signal is sent to the system control The system control issues an additional warning tone 4 OPERATION 4 2 SETTING AND MONITORING Error messages If the machine control system detects a serious mal function The labelling operation is automatically halted An error message appears on the LED indicator of the operator panel yunun m Awarning message is displayed in the format E_nn pe is on FEED E stands for error nn is a two digit numerical code An electronic signal is issued at the same time The signal can be further processed by an external con 51 Example The error message E__6 is displayed on the operator trol system panel For an explanation of the error messages and notes on fault elimination see chapter Operational mal functions Example 51 The label ribbon is torn The error message E_ 6 appears on the operator panel An electronic signal is sent to the system control The system control issues an additonal warning tone and stops the conveyor belt 4 OPERATION 4 3 PRODUCT DATABANKS 4 3 1 Functions 4 3 2 Loading product data banks Task specific settings that do not need to be modified Please observe for daily operation I CAUTION Erroneous settings can lead t
6. 2 EQUIPMENT DESCRIPTION 2 1 OVERVIEW 2 1 4 Design versions The ALS 380 labeller is available in 4 different versions depending on the taskat hand Top labeller right hand version Labelling from above onto the upper side of the product 3 The products are conveyed from left to right The dispensing edge is located on the right side Side labeller right hand version Labelling from the side onto one of the product s sides 4 The products are conveyed from left to right The dispensing edge is located on the right side 3 Top labeller right hand version A ALS 380 labeller B Product on conveyor line C Labelled product 4 Side labeller right hand version A ALS 380 labeller B Product on conveyor line C Labelled product 2 EQUIPMENT DESCRIPTION 2 1 OVERVIEW Top labeller left hand version Labelling from above onto the upper side of the product 5 The products are conveyed from right to left The dispensing edge is located on the left side Side labeller left hand version Labelling from the side onto one of the product s sides 6 The products are conveyed from right to left The dispensing edge is located on the left side e Labeller operation is described in these instruc 1 tions based on the top labeller right hand de sign version Other design versions are only considered if their descriptions or illustrations differ
7. 3 1 INSERT THE LABELLING MATERIAL Thread the label ribbon at the rewind unit gt Thread the label ribbon around the deflection rollers and the dancer armrollers as shown in figure 18 gt Open the spreader mechanism of the rewinding roll er using the lever 18C When the spreader mechanism is open the red point on the rewinding roller is visible gt Insert the end of the label ribbon into the slot on the rewinding roller gt Rotate the rewinding roller counter clockwise until the label ribbon is under tension e After a label roll is passed through the backing 1 material roll rests firmly on the rewinding roller The spreader mechanism allows the diameter of the rewinding roller to be decreased The backing material roll can then be easily re moved gt Only put the label ribbon on the rewinding roller when the spreader mechanism is open red point visible gt Donotclose the spreader mechanism before the backing material is removed from the re winding roller 18 Guides for the label ribbon in the dancer arm rewinding section A Deflection rollers B Dancer arm roller C Lever for the spreader mechanism of the rewinding roller in the open position 3 PRIOR TO OPERATING 3 2 MECHANICAL SETTINGS WARNING Risk of injury due to moving or rapidly rotat ing parts gt Before carrying out the mechanical set tings ensure that the machine is switched off at the ma
8. gt Tighten the central lock 23B e _ For recurring adjustments when products are changed gt Use the scales on the guide columns 23 Adjustable dispensing edge optional 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN 4 1 1 Starting the machine Before each use the control system must be adapted to the inserted label material During this the label dis tance is detected and the photoelectric sensor at the dispenser head is adapted to the transparency of the labels and of the backing material This process is called material initialisation Automatic material initialisation 24 FEED key Initialising material at switch on gt Press and hold the FEED key 24 and switch on the machine at the main switch 25A The message AUTO appears on the operator panel The machine slowly starts up and dispenses a label The label distance is automatically measured The photoelectric sensor is automatically adapted gt Release the FEED key once a label gap has passed the photoelectric sensor at the dispenser head If the initialisation was successful ON appears on the operator panel When the FEED key is pressed a label is dis a pensed 25 Main switch on the housing If the initialisation was unsuccessful The message FAIL appears on the operator panel gt Switch off and automatically re initialise the ma chine or exPeRTS gt Manually init
9. User MANUAL 051790 A ve DENNISON Link information to your product 1 1 1 1 1 1 2 1 2 1 1 2 2 1 2 3 2 1 2 1 1 2 1 2 2 1 3 CONTENTS Please observe the following General information 4 Validity and applicability of this manual 4 Gontents sas mens none eae E aE ead Sta alsa 4 Technical State 0 0 0 cece eee 4 Copyright notice 0 eee eee eee 4 Manufacturer 0 0 0 0 00 ee eee 4 Conventions and information 5 Explanation of symbols 5 Warnings concerning dangers and risks 5 Illustrations 0 0 0 0 ees 5 Supplemental information 5 Directional information 5 6 Safety instructions 7 Information and qualifications 7 Pay attention to the information 7 Information must be made available 7 Ensure necessary qualifications 7 Machine operating safety 8 Appropriate use 0 000 cee ee eee 8 Protect against injuries that can result from electrical current 2 0005 8 Protect against injuries that can result from mechanical actions 205 8 Protection against chemicals 8 Before every production start Operator s obligation and service personal to exercise Care 2 ee 9 Operating personnels obligation to exercise ClO eve Mck Stan kien S
10. 16C Thread the label ribbon around the deflection roller 16E dancer armroller 16A and drive roller unit 16D Form a loop after the drive roller unit and guide the label ribbon over the operator panel support 16F Swing the pressure roller and web brake back into position The pressure roller and braking brush click into op erating position 16 Guides for the label ribbon in the unwinding section A Dancer arm roller B Pressure roller C Braking brush D Drive roller unit E Deflection roller F Operator panel support 3 PRIOR TO OPERATING 3 1 INSERT THE LABELLING MATERIAL Thread in the label ribbon at the dispens ing edge gt gt gt Swing up the pressure roller 17D behind the dis pensing edge Unthread approximately 2 m of label ribbon from the label roll Guide the label ribbon around the first deflection roller 17A and through the slot in the photoelectric sensor 17B for the dispensing edge Guide the label ribbon around the dispensing edge to the drive roller unit 17C Thread the label ribbon around the drive roller unit and the second deflection roller 17E Swing the pressure roller back into operating posi tion 17 Guides for the label ribbon at the dispensing edge A 1st Deflection roller B Label stop sensor C Drive roller unit D Pressure roller shown here in operating position E 2nd Deflection roller 3 PRIOR TO OPERATING
11. 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN 4 1 4 Tandem operation 33 Two labellers in tandem arrangement A The active labeller label roll comes to its end B Labeller in standby with full label roll LOCK appears on the operator panel Principle of operation In tandem operation two labellers are arranged one behind the other Only one of the labellers is in opera tion at a time The other remains in standby If the active labeller reports the end of the label roll it shuts down The other labeller takes over the task of la belling The shut down labeller can now be loaded with label material The LED indicators on the operator panels of the two machines indicate their respective operating states ON on the operator panel of the currently active ma chine LOCK on the operator panel of the machine in standby W_ 5 if the respective machine has shut down due to reaching the end of the label roll During automatic switch over from one machine to the other the distance between the two machines and their arrangement are taken into consideration As a rule unlabelled products can be prevented This guarantees uninterrupted labelling operation Reloading periods do not affect the course of production The first machine in the production line is designated as the master device the second is designated as the slave device In tandem operation the dispensing speed is automat ically adapte
12. 2 OPERATOR CONTROLS 2 2 1 Operator panel LED indicator Display of functions setting values operating states error messages and warning messages If the LED indicator is ON The machine is in labelling mode Each time the product sensor is triggered a label is dispensed If the LED indicator is OFF Labelling mode is switched off Keys FEED When this key is pressed the machine dispenses a label PRIOR previous function Paging through the functions in the menu to see the previous function page upward Within a function increase the current value NEXT next function Paging through the functions in the menu to see the next function page downward Within a function decrease current value ENTER Activate or switch off labelling mode Call up or end functions Acknowledge error and warning messages Py Depending on the menu and the operating 1 state of the machine special key functions are also available Where special functions are available they are described in the relevant chapter Q FEED B Ake V NEXT D AVERY FUNCTION 7 380 l ENTER F 7 Operator panel for the ALS 380 A LED indicator B FEED key C PRIOR key D NEXT key E ENTER key o 2 EQUIPMENT DESCRIPTION 2 2 OPERATOR CONTROLS 2 2 2 Main switch The main switch 8 is located to the left on the
13. PRIOR key Settings are possible in 0 1 mm steps Minimum 10 mm Maximum 999 9 mm gt Confirm the setting using the ENTER key and exit the POS function m Note POS actually sets the path that the prod 1 uct follows from the product sensor to the trig AVA AN gering of the labelling If the product sensor is located at the level of the dispensing edge this is the distance between the leading edge of the A B Cc 45 A Value for the POS function product and the label 46 Symbols on the operator panel keys A NEXT key B PRIOR key C ENTER key FOS Q B 47 POS display on the operator panel 4 OPERATION 4 2 SETTING AND MONITORING 4 2 5 Automatic material initialisation INIT Also refer to chapter Activation and shut down gt Inthe standard menu press the NEXT or PRIOR key until INIT 48 is displayed on the operator pan el Call the INIT function by pressing the ENTER key Press and hold the FEED key l 48 INIT displ th t The message AUTO appears on the operator panel 48 Di a The machine slowly starts up and dispenses a label T Q FEED gt gt gt Release the FEED key once a label gap has passed the photoelectric sensor 49A at the dispenser head If the initialisation was successful ON appears on the operator panel When the FEED key is pressed a label is dis pensed If
14. The machine stops after three products in a row are not labelled The error message E__11 appears on the operator panel In the extended menu gt Call up the MLAB function gt Set the desired value Possible settings 0 10 products gt Confirm the setting using the ENTER key and exit the function 4 4 13 Electronic transmission ratio of the RPM transmitter EGRA Compensation factor for RPM transmitter when op erating with automatic dispensing speed adjustment Refer to chapter Automatic dispensing speed APSF page 67 For ALS 380 HS refer to the Service Guide Cor or ra 70 Three products in a row were not labelled 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 14 Advance print start PDT When using a printer optional The printing process can be started even in the final phase of the label feed In so doing the printer stamp is already moving toward the label ribbon even before the label has come to a standstill this shortens the printing process Using the PDT function you can determine when after how many motor strokes before label stop the printing process will be started In the extended menu gt Call up the PDT function gt Set the desired value Possible settings 0 50 motor strokes For the setting 0000 the label stop and printer start coincide gt Confirm the setting using the ENTER key and exit the function e Th
15. The operator panel of this machine indicates LOCK As soon as the product sensor sends a start signal the labelling operaton is activated e fthe currently active machine is switched off at 1 the main switch while the second machine is in standby The second machine is automatically activat ed gt Do not interrupt tandem operation using the main switches gt Only actuate the main switch if the operator panels of the two machines indicate OFF 37 FEED key 4 OPERATION 4 2 SETTING AND MONITORING 4 2 1 Settings in the standard menu Overview Function Brief description Display ON Activate labelling mode OFF End labelling mode INIT Automatic material initialisation VELO Dispensing speed STOD Distance between dispensing edge and leading edge of the label POS Distance between leading edge of product and label 38 Functions in the standard menu Calling up menu The standard menu is automatically started when the machine is switched on if it was active before the last shut down of the machine Piped OQ FEED Ifthe standard menu does not automatically acti vate The machine will switch off and back on when y the NEXT 39B key is pressed PRIOR A A N FUNCTION Call up function VY NEXT B The desired function can be selected by pressing AVERY aon the NEXT 39B and PRIOR 39A keys The funct
16. as well as to use equivalent components that keep pace with the current state of technology in lieu of the specified components change information contained in this manual An obligation to extend these modifications to previous ly delivered machines is excluded gt Copyright notice All rights to this operating manual are assigned to Avery Dennison Transmission reprinting or any other means of reproduction of this manual whether whole or in part are not allowed without prior written permission Third parties in particular competitors are not to be allowed access to information derived from this manual Printed in Germany Manufacturer Avery Dennison Deutschland GmbH Ohmstra e 3 D 85386 Eching Phone 49 8165 925 0 FAX 49 8165 3143 http www machines averydennison com 1 1 GENERAL INFORMATION 1 1 2 Conventions and information Explanation of symbols In order to facilitate legibility and an overview the vari ous types of information used herein are categorised and identified with certain symbols Sentences that are introduced by an arrow contain pro cedural instructions gt Carry out procedural instructions one after the other in the prescribed order The following information is introduced with a dash List items Descriptions of conditions Description of previous work steps Prerequisites for implementing actions described in the following passage Warnings concerning dangers an
17. housing The main switch is used to switch the machine on and off WARNING Contact with energised components can re sult in life endangering currents through the body as well as burns Voltage continues to be present in the housing even when switched off gt Only put the machine into operation when installed in a correctly installed housing gt Maintain the machine in a dry condition 8 Main switch on the housing 17 2 3 CONTROL SYSTEM 2 3 1 Brief description All of the machine s functions are electronically controlled Using the operator panel the operators cal ibration technicians or service personnel have several options for adapting the machine s functions to current requirements The LED indicator gives the operator feedback mes sages regarding the current operating state of the ma chine Error messages or warning messages appear on the display as necessary Before each operation the operator must check and adjust the occasionally changing settings such as the label position on the product or the dispensing speed These settings can simply be input at any time by the operator at the operator panel Task specific data such as label distance or product length are programmed at the beginning of a job As a rule the settings are not modified as long as the job is being processed This data input requires in depth knowledge and may only be carried out by trained and instructed personne
18. it Electro pneumatic Applicator EP Applicator The applicator uses suction to take the label from the dispensing edge Then a pneumatic cylinder ex tends and presses the label onto the product Reverse Electro pneumatic Applicator REVP Applicator The applicator uses suction to take the label from the dispensing edge Then a pneumatic cylinder with the label traverses into the application position and waits there for the product When the product reaches the pneumatic cylinder it presses the label onto the product By means of the APPL function in the extended menu the controller is adjusted to the applicator currently in use 4 OPERATION 4 6 APPLICATOR OPTIONAL 4 6 2 Functions in the extended menu Please observe the following CAUTION Erroneous settings can lead to production setbacks damage to the machine and sys Only specially trained and instructed per sonnel may alter the settings in the ex tended menu Calling up the extended menu gt Simultaneously press the NEXT and PRIOR keys CODE appears on the LED display gt Enter the password 73 N V vV The following appears on the LED display for ap i i prox 1 second The extended menu is active 73 Key sequence password for the extended menu Applicator type APPL Set the applicator type used or switch off the appli cator In the extended menu gt Call up
19. the APPL function gt Set the desired type Possible settings ASA Air Stream Applicator EP Electro pneumatic applicator REVP Reverse electro pneumatic applicator DIR Dispense directly from the dispenser head without using the applicator gt Confirm the setting using the ENTER key and exit the function 4 OPERATION 4 6 APPLICATOR OPTIONAL EP cylinder dwell time APT1 Dwell time for the EP cylinder In the extended menu gt Call up the APT1 function gt Set the desired value Settings are possible in 1 ms steps 1 7500 ms gt Confirm the setting using the ENTER key and exit the function Blowing time APT2 When using a blowing applicator Dwell time for blowing the label on the product In the extended menu gt Call up the APT2 function gt Set the desired value Settings are possible in 1 ms steps 1 7500 ms gt Confirm the setting using the ENTER key and exit the function Delay time APT3 When using an EP applicator Delay of the signal air blow The signal controls the air blow which blows the la bel onto the underside of the applicator The value for APT3 is the delay between the start of label dis pensing and activation of the air blow In the extended menu gt Call up the APT3 function gt Set the desired value Settings are possible in 1 ms steps 1 5000 ms gt Confirm the setting using the ENTER key and exit the function
20. the initialisation was unsuccessful The message FAIL appears on the operator panel gt Initiate the INIT function again or experts gt Manually initialise the material employing qualified calibration technicians If the FEED key is not pressed down when INIT is displayed on the operator panel but only lightly actuated The values for the label distance setting and the label stop sensor will be deleted provided these values are stored in the control unit Continual feed at maximum speed is trig gered The continual feed only stops after a mal function occurs gt To prevent operational malfunctions switch off the machine at the main switch as soon as possible e 4 OPERATION 4 2 SETTING AND MONITORING 4 2 6 If errors occur Warning messages If the machine control system detects a malfunction but the labelling operation does not have to be inter rupted A warning message appears on the LED indicator of the operator panel A warning message is displayed in the format O FEED W_nn W stands for warning nn is a two digit numerical code An electronic signal is issued at the same time The 50 Example The warning message W__4 is displayed on the op signal can be further processed by an external con erator panel trol system For an explanation of the warning messages and notes on fault elimination see chapter Operational malfunctions
21. to the machine gt Do not use cleaning agents that could damage or destroy the painted surfaces lettering the display identification plates electrical components etc Ob serve the information provided by the cleaning agent manufacturer gt Do not use abrasive or plastic dissolving cleaning agents gt Do not use any acidic or alkaline solu tions 5 AFTER OPERATION 5 1 CARE AND CLEANING Remove paper waste gt Wipe off all paper waste dust from all rollers and edges gt Clean the optics of the photoelectric sensors with a soft brush or a soft tissue Braking brushes gt Loosen the stud bolts 75A and remove the braking brushes gt Remove adhesive residues gt Turn the braking brushes and reinstall them so that the side opposite the deformed bristles bears the load 75 Braking brush 5 AFTER OPERATION 5 1 CARE AND CLEANING Capacitive sensor at the dispenser head Only if the labeller is equipped with a capacitive sensor 76A instead of the proper photoelectric sen sor gt Remove the knurled thumb screw 76B gt Remove 2 screws on the underside 77A gt Remove the upper part of the housing 78A gt Clean the sensor surfaces 78 arrows with soft lint free rags Reassemble the sensor gt gt Test the sensor adjustment Leuze 3802 nlo CE GK 14 24 L 76 A Capacitive sensor B Knurled thumb screw 77
22. triggers the dispensing of a label label feed using the set val ues for dispensing speed label distance etc The dispensing of labels automatically runs in the same manner for the following products 30 The product sensor A has detected a product B at the dis pensing edge and sends a start signal 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN Unwind unit A loop forms in the loop space as a buffer between A the unwind unit and label dispensing 31 arrow A photoelectric sensor in the loop space monitors the loop Ifthe loop becomes too large the control system au tomatically lowers the unwinding speed The dis pensing speed does not change The dancer arm 31A swings approximately into the centre position Rewind unit The multiple deflections with the spring loaded dancer arm act as a buffer between the label output and the rewind unit During synchronous operation the dancer arm is approximately in the centre position 31B Ifnecessary the control system automatically slows the rewinding speed The dispensing speed is not 31 ALS 380 in labelling mode affected by this 4 1 3 Stop end the label dispensing gt Press the ENTER key The unwind unit dispenser drive and rewinding unit shut down pe pean OFF appears on the operator panel 32 pti T FEED l A 32 OFF display on the operator panel
23. 80 The control system calculates the permanent position and speed of the products The resulting values are used for controlling label feed unwinding and rewinding and are constant ly monitored and regulated Fluctuations in the convey or belt speed are automatically compensated for If the conveyor belt stops the label dispenser also stops The conveyor belt can stop even while a label is being dispensed The label feed is then stopped as well Only when the belt starts running again does the label feed move the label to the next gap on the label ribbon Conveyor belt and label dispenser are operating in per fect synchronisation As a prerequisite for this the speed sensor must be correctly adjusted Depending on the operating conditions the relationship between the dispensing speed and the conveyor belt speed must be finely adjusted the EGRA function Only servicing technicians are permitted to con exrerts figure the label dispenser for APSF mode For further information refer to the Service Guide 4 OPERATION 4 5 AUTOMATIC DISPENSING SPEED APSF 4 5 1 Electronic transmission ratio of the RPM transmitter EGRA Required compensation factor for the RPM trans mitter For ALS 380 HS refer to the Service Guide Setting the compensation factor gt Calculate the setting value for EGRA 100 EGRA ET A resolution of the RPM transmitter used in mm pulse Possible settings 100 650 factory se
24. A Fastening screws for the housing on the underside A eo e oe 78 A Upper part of the housing with sensor surfaces arrows 6 OPERATIONAL MALFUNCTIONS 6 1 WARNING MESSAGES 6 1 1 Please observe 6 1 2 If a problem occurs 1 CAUTION The control system detects a problematic or unaccept Improper handling of the machine especial able situation ly changes to the settings can lead to seri A warning message is displayed on the operator ous damage to the machine and system and panel can cause work related accidents As a rule the labelling operation is continued if the Only the responsible servicing techni operator does not stop the machine cians or customer service personnel are authorized to make changes to the set If the cause of the warning message is eliminated tings in the configuration menu The warning code is no longer displayed gt Ensure that the other settings are carried out exclusively by specifically trained and knowledgeable personnel Observe the expert symbols gt Observe the additional information in this operating instruction or in the service guide 6 1 3 Warning messages Message Description Possible causes and remedies W_0 Product was not labelled gt Remove the unlabelled product Several labels are missing from the label ribbon gt Replace the label roll if the error occurs frequently The distance between the products on the convey
25. Ensure necessary qualifications gt gt Only allow the machine to be operated adjusted and serviced by instructed and authorised person nel Adjustment tasks via the expanded menus as well as programming and administration of product data bases are only to be performed by qualified and ap propriately trained personnel or by the responsible servicing technician The responsibilities for operation adjustment and servicing of the machine must be clearly defined and consistently maintained Moreover personnel are to be regularly instructed about work safety and environmental protection is sues Operator qualifications Instruction of the operating personnel must ensure vu that operating personnel can use the machine inde pendently and without posing a danger that operating personnel can remedy minor opera tional malfunctions themselves Train at least 2 person to operate the machine Make label materials for test purposes available in sufficient quantities Qualifications for adjustment tasks Settings in the expanded menus of the control EXPERTS Software require knowledge based on experi ence The adjustment personnel must be familiar with how the labeller functions Adjustment personnel must be familiar with the entire system into which the labeller is in tegrated Adjustment personnel must be able to cor rectly apply the functions in the expanded menu system to appropriately address
26. GS IN THE EXTENDED MENU In addition when using a printer optional PDT Print delay PDWT Printer dwell time 55 Additional functions for printers Additional functions when using an Applicator optional APPL Set the applicator type used APT1 Set the dwell time for the EP cylinder APT2 Dwell time for blowing the label on the product APT3 Idle time of the applicator between two labelling processes APT4 Fine tuning of the applicator dwell time in connection with APSF 56 Additional functions for the applicator 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 2 Activating an extended menu Please observe CAUTION Erroneous settings can lead to production setbacks damage to the machine and sys Only specially trained and instructed per sonnel may alter the settings in the ex tended menu Calling up menu To access the extended menu you must enter a password gt Simultaneously press the NEXT and PRIOR keys A N V V CODE appears on the LED display gt Enter the password 57 The following appears on the LED display for ap prox 1 second x 57 Key sequence password for the extended menu The extended menu is active Call up function gt Repeatedly press the NEXT or PRIOR key until the desired function is shown on the display gt Call up the function using the ENTER key gt To exit the fu
27. OL SYSTEM 2 3 2 Menus for operators and calibration technicians ALS Menu Standard menu Extended menu Product databanks Functions ON ON ON OFF OFF OFF INIT INIT PDO1 VELO VELO PDO2 STOD STOD PDO3 POS POS PD04 POS 2 PDO5 POS 3 PDO6 VERT PDO7 CONT PD08 E SS PDO9 LPIT PD10 PRDL PD11 P_S_ S_S_ MLAB PDT PDWT EGRA TMOD APPL APT1 APT2 APT3 APT4 LOAD SAVE DEL QUIT Activating a Main switch NEXT PRIOR NEXT y Main switch menu EXPERTS w PRIOR id AMM 1 Not ALS 380HS 19 2 EQUIPMENT DESCRIPTION 2 3 CONTROL SYSTEM 2 3 3 Monitoring functions During labelling operation the electronic control sys tem and the sensors monitor the following functions Dispensing a label to each product A photoelectric sensor product sensor sends a sig nal when a product reaches the dispensing edge 9B The signal from the product sensor trig gers the label feed for a single label If individual labels are missing from the label ribbon the label feed compensates for this and advances the label ribbon by one additional label distance la bel compensation Iflabel compensation does not take place before the next start signal of the product sensor the product does not get labelled A warning message appears at the operator panel Ifthe number of unlabelled products exceeds a cer tain val
28. abelled products is experts belt is insufficient greater than the amount set in the M4 5 Increase the product distance MLAB function gt For circumferential labelling Increase the rotation al speed P The product triggers several start signals caused by experts reflections for example A gt Adjust the product length PRDL function y x When using a printer the printing time is too long experts gt f possible decrease the printer dwell time PDWT function gt Start printing process before label stop PDT func tion Several labels are missing from the label ribbon 7 q experts gt Replace label roll A or gt Increase value for MLAB if possible E 12 Invalid setting value y A serious memory error has occurred Factory settings are activated see experts The control system needs to be reconfigured by a appendix a servicing technician or Avery Dennison s custom er service refer to the Service Guide E 13 Label roll is completely consumed gt Replace label roll Labels are no longer detected at the label stop sensor E 14 Too many products between product a Product sensor located too far from dispensing edge sensor and dispensing edge experts A maximum of 7 products can be located between 4 the product sensor and the dispensing edge gt Change the position of the product sensor gt Subsequently correct the POS setting a The product triggers several start signals caused by e
29. allow the sensitivity of the sensor to be adjusted auto matically When using labels with only a slight difference in the transparency of the label and the backing material per forated labels or labels with block outs gt Manually adjust the sensors as described below Non standard photoelectric sensors In series production the labeller is equipped with a photoelectric sensor manufactured by Wenglor When using transparent labels or labels with a very slight difference in the transparency of the label and the backing material It is possible that the gap between two labels will not be detected Instead of just one label two or more labels might be dispensed Use of a mechanical or capacitive sensor is recom mended A mechanical sensor is only of limited use at high dispensing speeds When using a non series production photoelectric sen sor gt Reduce the setting value for CONT to NONE For information on connecting a mechanical or ca pacitive sensor see the Service Guide 57 Automatically adjusting the photoelectric sensor gt Press and hold the FEED key and switch on the ma chine at the main switch The message AUTO appears on the operator panel or gt When the machine is switched on call up the INIT function Press and hold the FEED key The machine slowly starts up and dispenses a label The label distance is automatically measured The photoelectric sensor is adjusted Release th
30. and calibration technicians 0 0 cee ees 19 Monitoring functions 20 Dispensing a label to each product 20 Label supply 200 eee eee 20 If errors OCCUr St ees 20 Prior to operating Insert the labelling material 21 Prerequisites 0 0 ee 21 Insert the label roller 21 Remove the old backing material 21 Remove adhesive residues 21 Insert new label roll 22 Threading the label ribbon 23 Overview of the threading path diagram 23 Thread the label ribbon at the unwind unit 24 Thread in the label ribbon at the dispensing 3 2 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 4 1 4 1 1 4 1 3 4 1 4 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 4 2 6 Mechanical settings 27 Setting the ribbon guides 27 Operator panel support 05 27 Deflection rollers on the rewind unit 27 Adjusting the braking brushes 28 Adjusting the pressure rollers 29 Adjust the pressure roller unit optional at the dispensing edge 4 30 Adjust optional the position of the dispensing edge 00 ee eae 31 Adjusting vertically 000 31 Operation Activation and shut down 32 Starting the machine 32 Automatic material initialisation 32 Manually initiali
31. bank using the NEXT or PRIOR key 11 product databanks are available Using the ENTER key save the current settings in the selected product databank 4 44 4 Exit the extended menu using QUIT If the selected product databank already contains data The question YES appears on the display gt Confirm the query by pressing the ENTER key to overwrite the selected product databank with the new data Should the product databank not be overwritten gt Press the NEXT key until QUIT appears on the dis play gt Press the ENTER key The selected product databank is closed without be ing saved gt Select another product databank to save the current settings Documenting product databanks gt Document the contents of the product databanks in a table Use the example copy in the appendix 4 OPERATION 4 3 PRODUCT DATABANKS 4 3 4 Deleting a product databank In the extended menu gt Call up the DEL function gt Select the desired product databank using the NEXT or PRIOR key Only product databanks that contain data are shown The indicator with the last activated product data bank blinks This product databank cannot be delet ed gt Delete the selected product databank by pressing the ENTER key gt Exit the extended menu using QUIT If the last activated product databank is deleted gt Select another product databank using the LOAD function The desired produc
32. d is running E 3 The photoelectric sensor in the loop Refer to E__1 and E_ 2 First check the loop formation space does not detect the loop for mation and the label stop sensor does not detect the labels E 4 Rewind unit problems Label roll empty gt Replace label roll Label ribbon torn gt Rethread the label ribbon at the rewind unit Rewinding motor runs too slowly or is defective experts Setting or adjustment by servicingtechnician is re quired refer to the Service Guide E 5 Photoelectric sensor in the loop RefertoE 1andE_ 4 space does not detect the loop for mation and problem with the rewind ing unit E 6 Label stop sensor does not detect Label ribbon torn the labels and problem with the re wind unit gt Rethread the label ribbon at the rewind unit 6 OPERATIONAL MALFUNCTIONS 6 2 ERROR MESSAGES Message Description Possible causes and remedies E 7 Photoelectric sensor in the loop Refer toE_1 E__2 andE__4 space does not detect the loop for mation label stop sensor does not detect the labels and problem with the rewind unit E_10 Error in the applicator section op a Only when an applicator is used tional w Inspection of the compressed air connection and the neutral position sensor by servicing technicians is re quired see the operating manual of the applicator E 11 Many products are not labelled The The distance between the products on the conveyor 7 N ne a number of unl
33. d risks Important text passages which must absolutely be fol lowed are particularly marked for special attention DANGER AN A danger notice indicates an imminent hazardous situation which if not avoided could result in death or serious injury of the personnel The notice contains instructions on how to avoid or prevent the danger s gt The instructions must be followed WARNING AN A warning notice indicates risks which could result in death or serious injury of the personnel The notice contains safety in structions on how to safeguard possibly af fected personnel gt The instructions must be followed CAUTION A caution notice indicates risks which if unheeded could lead to material damage or bodily injury minor injuries The notice contains instructions on how to prevent damage or injury gt The instructions must be followed ALS Illustrations When required text passages are accompanied by il lustrations The reference to an illustration is indicated by typesetting the illustration number in square brack ets Capital letters following an illustration number e g 12A refer to the corresponding position indicated in the illustration Supplemental information The Experts symbol earmarks activities that ExPeRTS Only to be performed by knowledgeable and trained personnel e The information symbol indicates notices and 1 recommendations as well as additional helpful information Operat
34. d to the speed of the conveyor belt also see chapter Automatic dispensing speed adjustment 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN Prerequisites Both machines are configured and tested for tan dem operation and automatic dispensing speed ad justment Label material is inserted machines are switched on material is initialised OFF appears on the operator panels of both ma chines On the machine that is to begin labelling first gt Press the ENTER key 34B The operator panel of this machine indicates ON 34A This machine is activated On the other machine gt Press the ENTER key The operator panel of this machine indicates LOCK Start dispensing labels The conveyor belt starts up The first product reach es the product sensor 35A of the activated ma chine The product sensor sends a start signal The machine with the ON indication starts dispensing 35labels B The machine with the LOCK indication remains in standby 35C Q re l v PRIOR FUNCTION NEXT AVERY FUNCTION 2 380 l ENTER 34 Operator panel for the ALS 380 A ON LED indicator B ENTER key 35 Start of the label dispensing in tandem operation A The first product has reached the product sensor of the ma chine that is to begin labelling first B The machine with the ON indication starts dispensing labels C The machine with
35. e FEED key once a label gap has passed the photoelectric sensor at the dispenser head If the adjustment measurement was successful ON appears on the operator panel If the adjustment measurement was not successful The message FAIL appears on the operator panel gt Manually adjust the sensor 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU Manually adjusting the sensor In the extended menu gt Call up the CONT function gt Insert the backing material without a label under the photoelectric sensor gt Press the PRIOR key until the yellow LED on the photoelectric sensor 61A illuminates gt Press the NEXT key in stages until the yellow LED extinguishes again gt Make note of the value displayed when the LED ex tinguishes Value of the backing material gt Insert the backing material with a label under the photoelectric sensor LED A illuminates The LED illuminates gt Press the NEXT key until the LED extinguishes gt Make note of the value displayed when the LED ex tinguishes Value of the abel If the LED does not extinguish even at the lowest value 1 gt Write down 1 as the value of the label gt Calculating the setting value for CONT backing material label CONT 5 gt Enter the calculated setting value using the NEXT or PRIOR key gt Save the value using the ENTER key and exit the CONT function Test the setting gt Pull the label ribbon
36. e printer stamp is blocking the label feed The printer stamp should first contact the la bel ribbon only after the label has come to a standstill gt If the printer stamp prematurely contacts the label ribbon reduce the PDT setting value 4 4 15 Printer dwell time PDWT When using a printer optional Set the dwell time for the printer printing time In the extended menu gt Call up the PDWT function gt Set the desired value Settings are possible in 1 ms steps Minimum 0 ms Maximum 1000 ms gt Confirm the setting using the ENTER key and exit the function e The printer stamp is blocking the label feed 1 gt When setting the printing time ensure that the printing process has finished before the next label feed begins The greater the labelling speed the less the possible printing time 71 The printing process starts while the label feed is still transport ing the next label ALS 4 4 SETTINGS IN THE EXTENDED MENU 4 4 16 Tandem operation TMOD Activate and deactivate tandem operation Refer to chapter Tandem operation in the service guide 4 4 17 Applicator type APPL When using an applicator optional Set the applicator type used or switch off the applicator Refer to chapter Applicator optional page 52 4 4 18 EP cylinder dwell time APT1 When using an EP applicator optional Set the dwell time for the cylinders R
37. eader mechanism ALS 380 HS 55 kg Label sensor Manual or automatic set ting Casing Operation programmable can be set via the operator panel Covering for the control Polyurethane PUR The settings can be stored electronics 10 mm thick in 11 data banks Front plate Aluminium anodized Speed control Automatic dispensing 15 mm thick speed with RPM transmitter Electrical system Power consumption 500 VA Labels Mains connection Label width incl backing material max 155 mm Label length at maximum dispensing speed min 16 mm max 250 mm Label roll Outer diameter max 400 mm Core diameter 76 2 mm Distance from dispens ing edge to label sen min 20 mm sor 1 Longer labels are possible when product distance is increased accordingly Ambient conditions Temperature Operation Storage 5 C to 40 C 5 C to 70 C Relative humidity 30 to 80 not condensing 12 Nominal voltage 110 V 120 V 130 V 200 V 220 V 230 V 240 V Frequency 50 Hz 60 Hz Type of protection IP41 protected against vertically falling drops of water not protected against sprayed water Drive system 2 stepping motors 1 AC motor 1 Customer options Control system Control electronics Integrated Options V24 interface Frequency inverter for motor control Emissions Sound pressure level at a distance of 1 m 75 db A
38. efer to chapter Applicator optional page 52 4 4 19 Blowing time APT2 When using a blowing applicator optional Set the dwell time for blowing the label on the product Refer to chapter Applicator optional page 52 4 4 20 Delay time APT3 When using an EP applicator optional Delay of the signal air blow Refer to chapter Applicator optional page 52 4 4 21 Fine tuning of the dwell time APT4 When using an applicator optional Fine adjust the dwell time of the applicator in combina tion with the automatic dispensing speed adjustment By doing this the accuracy of the label position on the product can be optimised Refer to chapter Applicator optional page 52 66 4 4 22 Delete a product data bank load LOAD Selecting and loading a product data bank Refer to chapter Product databanks page 48 4 4 23 Create save product data bank SAVE Create a new product data bank Refer to chapter Product databanks page 48 4 4 24 Delete a product data bank DEL Refer to chapter Product databanks page 48 4 OPERATION 4 5 AUTOMATIC DISPENSING SPEED APSF 72 A Speed sensor on the conveyor line The automatic dispensing speed APSF makes it pos sible to automatically adapt the dispensing speed to the speed of the conveyor belt The speed of the conveyor belt is picked up by a speed sensor and transmitted to the control system of the ALS 3
39. es ewe ae oe 9 Equipment description OVEIVIOW eee ee Shoe oes 10 Structural elements 10 Principle of operation 11 Technical data 00005 12 Characteristic values 12 Labels Zoiie e bets te a r ule ory whee 12 Ambient conditions 05 12 DIMENSIONS 2228 eee Oa eee a 12 Casing oa ea deen kote dene ee ee 12 Electrical system 2000 c ee eee 12 Control system 2 200 005 12 EMISSION Serio fe eens hse tes echt nce he 8 12 2 1 4 2 2 2 2 1 2 2 2 2 3 2 3 1 2 3 2 2 3 3 3 1 3 1 1 3 1 2 Design versions Top labeller right hand version Side labeller right hand version 13 Top labeller left hand version 14 Side labeller left hand version 14 OPTIONS sed ee ae Sa ees els Bayh Sead 15 High speed processing version ALS 380 HS 15 Serial interface 0 0 cee eee eee 15 Roll diameter control 15 Adjustable dispensing edge 15 Printer eeri r eae 4 Be ow MP e ow Saeed 15 AppliGatori s sigs sae eee ee see vas ee eed 15 Operator controls 16 Operator panel 16 LED indicator 005 16 KOYSi eee antl aaa lane aes ah ane Sane PEA EOE 16 Main switch 0 0 eee 17 Control system 18 Brief description 18 Menus for operators
40. ety gear in accordance with the regulations e g wear hair nets and protec tive eye glasses vu 3 1 2 Insert the label roller WARNING Risk of injury due to moving or rapidly rotat ing parts gt Before inserting the label roller ensure that the machine is switched off at the main switch gt Never switch on the machine before the label ribbon has been completely thread ed into position Remove the old backing material If backing material remains on the rewinding 12A roller gt Swing the lever 12C at the rewinding roller over the red 12B point The tension of the rewinding roller spreader mecha nism is relieved Remove the rewound backing material Remove adhesive residues gt If necessary clean the following components Dispensing edge Deflection rollers and drive roller unit in the dispens er head Dancer arm rollers and deflection rollers Rewinding roller 3 1 INSERT THE LABELLING MATERIAL 12 Remove the backing material from the rewinding roller A Old backing material B Red point on the rewinding roller C Lever for the spreader mechanism of the rewinding roller 3 PRIOR TO OPERATING 3 1 INSERT THE LABELLING MATERIAL Insert new label roll Only top labeller gt Loosen the set screw at the guiding rod 13C and swing the guiding rod to the side All design versions gt Rotate the knurled knob 13B cl
41. he product length A set in the PRDL function the machine ignores all start signals until the product has passed the dispenser head In the extended menu gt Call up the PRDL function gt Set the product length Settings are possible in 1 mm steps Minimum 5 mm Maximum 999 mm gt Confirm the value using the ENTER key and exit the function To set the product length the same as the label dis tance gt Set the value for PRDL to less than 5 The message AUTO appears on the operator panel The control system automatically sets the value for PRDL to the value of the label distance LPIT YJ 67 A Product length B Label C Product sensor D Product with recesses arrows 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 10 Polarity of the product sensor P_S_ The product sensor can optionally send the start signal if the leading edge of the product passes the sensor 68A the trailing edge of the product passes the sensor 68B In the extended menu gt Call up the P_S_ function gt Set the desired polarity Set the LEDG Triggered by leading edge Set the TEDG Triggered by the trailing edge Confirm the setting using the ENTER key and exit the function Rn 4 4 11 Polarity of the label stop sensor S_S_ The label stop sensor can optionally send the signal if the leading edge of the label passes the sensor 68A standard setting wi
42. ialise the material employing qualified calibration technicians 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN e The machine can also be automatically initial 1 ised after switch on by using the INIT function gt In the standard menu press the NEXT or PRIOR key until INIT 26 is displayed on the operator pan el Call the INIT function by pressing the ENTER key Press and hold the FEED key The message AUTO appears on the operator panel The machine slowly starts up and dispenses a label 26 INIT display on the operator panel vu ape Q gt Release the FEED key once a label gap has passed the photoelectric sensor at the dispenser head Ifthe initialisation was successful ON appears on the operator panel Manually initialise the material c B c m If automatic initialisation is not possible it does 1 not generally mean there is a malfunction Man ual initialisation is often required if the proper label stop sensor is not installed transparent labels are used labels with only a slight difference of trans parency between label and backing material are used perforated or otherwise blocked out labels are used 27 A Only by qualified calibration technicians exerts gt Calling up the extended menu gt Input the label distance using the LPIT LBA amp Label distanc i B Photoelectric sensor function C Labels with block outs perfo
43. ify a servicing technician 1 PLEASE OBSERVE THE FOLLOWING 1 2 SAFETY INSTRUCTIONS 1 2 3 Before every production start Operator s obligation and service personal to exercise care gt Ensure the following prerequisites correspond to the information of the operating manual The machine is correctly installed and appropriately configured for the requirements All necessary safety equipment is installed The machine has successfully completed at least one test run The machine is connected to the power supply gt The required personal safety gear e g hair nets must be provided Make sure that the safety gear is used in accordance with the regulations l Operating personnels obligation to exer cise care gt gt gt Verify flawless functioning of the safety equipment Check machine for visible damage Any discovered deficiency is to be reported immediately Use personal safety gear in accordance with the regulations e g wear hair nets Non required materials and objects are to be re moved from the working area of the machine Make sure that only persons authorised to work on the machine are within the working area of the ma chine Make sure that no one will be placed in a hazardous situation as a result of the machine startup 2 EQUIPMENT DESCRIPTION 2 1 OVERVIEW 2 1 1 Structural elements y EK A a bo F SNK S SRAN RER N A
44. in switch 3 2 1 Setting the ribbon guides Operator panel support gt Loosen the knurled thumb screws on the guide rings 19A gt Setting the ribbon guides Distance between label ribbon and front plate of housing 31 5 mm The label ribbon must run between the guides with as little play as possible but it must not be pinched gt Tighten the knurled thumb screws on the guide rings Deflection rollers on the rewind unit gt Slide the guide bushes onto the deflection rollers 19B The label ribbon must not run from the side behind the dispenser head 19 Ribbon guides 3 PRIOR TO OPERATING 3 2 MECHANICAL SETTINGS 3 2 2 Adjusting the braking brushes Mounting locations of the braking brushes In front of the operator panel support 20A On the vertical guide for the dispensing edge 20B gt Loosen the stud bolt 20C gt Align the braking brush centrally on the label ribbon gt Tighten stud bolts 20 Braking brushes 3 PRIOR TO OPERATING 3 2 MECHANICAL SETTINGS 3 2 3 Adjusting the pressure rollers Mounting locations of the pressure rollers On the drive roller unit of the unwind unit On the drive roller unit of the label feed gt Loosen the knurled thumb screws on the setting rings 21A gt Raise the pressure roller slightly and centrally align it on the label ribbon gt Secure the pressure roller a
45. ing materials A Operating materials e g lubricants or cleaning agents 1 PLEASE OBSERVE THE FOLLOWING 1 1 GENERAL INFORMATION Directional information Unless otherwise indicated the directional information mentioned in the text refers to the construction of the right hand version of Top Labeller See Figure 1 for the explanation of directional information Definition of directional information A Front B Rear C Upward D Downward E Left F Right G Clockwise H Counter clockwise 1 oo ll 1 2 SAFETY INSTRUCTIONS 1 2 1 Information and qualifications Pay attention to the information WARNING AN Reliable and safe operation of the labeller is only guaranteed if all necessary information is observed gt Read this operating manual thoroughly and observe all notices prior to operation gt Observe all additional safety and warning notices attached to the labeller gt Only allow qualified persons to operate and adjust the labeller Information must be made available This operating manual gt is to stored at the machine operating location and made accessible to the operator is to maintained in legible condition is to be made available to the new owner if the ma chine is sold gt _ gt gt Safety and warning notices attached to the labeller must be kept clean and legible Missing or damaged warning labels and plates are to be replaced ALS
46. ing speed APSF experts A check of the EGRA function by servicing techni cians is required refer to the Service Guide W_5 The roll diameter control optional Insert new labelling material reports the end of the label roll W_6 Data transmission error at the The cables plug connections and interface param V24 interface experts eters must be checked by servicing technicians re fer to Service Guide W_7 Label position on the product too gt Increase the setting value for POS decrease dispensing close to the product s leading edge speed VELO and high dispersing speed If this is not possible or the warning message yN EXPERTS reappears The settings in the configuration menu must be checked by servicing technicians refer to Service Guide 6 OPERATIONAL MALFUNCTIONS 6 2 ERROR MESSAGES 6 2 1 If a malfunction occurs If the control system detects a serious error If the cause of the error has been eliminated The labelling operation is stopped gt Acknowledge the error message by pressing the An error code is displayed on the operator panel ENTER key 6 2 2 Error codes Message Description Possible causes and remedies E 1 The loop space is not filled Label roll empty gt Replace label roll Pressure roller not closed gt Swing up the pressure roller on the drive roller units un wind unit and return it to its position pressing against the roller The pressure roller clicks neat
47. ion is called up by pressing the aA ENTER 39C key J 3 80 ENTER To exit the function press the ENTER key again lt 39 Operator panel in the standard menu 4 OPERATION 4 2 SETTING AND MONITORING 4 2 2 Label stop position STOD After the label is output the feed continues to operate until the next label is present at the dispensing edge To ensure that the labels separate completely from the dis A pensing edge it is advisable to allow the feed to run un til the next label projects slightly over the dispensing edge The label stop position is the distance between the leading edge of the next label and the dispensing edge 40A As a rule this distance should not be more than 3 mm The respective optimum setting value depends on the label material used the product speed the sur face characteristics of the product and other factors gt For problems during the labelling operation first check the label stop position gt Ifnecessary set the label stop position as described below Switch on the machine at the main switch 40 A Distance between dispensing edge and leading edge of the gt gt Inthe standard menu press the NEXT 41A or pee PRIOR 41B key until STOD 42 is displayed on the operator panel gt Call up the STOD function by pressing the ENTER 41C key The distance is shown on the operator panel in mm gt Set the desired distance u
48. l calibration technicians Databanks are available for variable or frequently re curring task settings The task specific settings can be saved in a databank If the settings are needed again after a product change it is not necessary to re input the data You only need to call up the corresponding databank In all 11 databanks are available Only calibration technicians may administer the product databanks 18 ALS It is also possible to modify the basic machine settings These are settings such as the motor s direction of ro tation These settings are not to be changed in normal operation They may only be changed by servicing per sonnel or the responsible servicing technician To give the operator a better overview the setting op tions for occasionally changing settings task specific data databanks and basic settings are grouped to gether in menus The standard menu extended menu product databanks and configuration menu The fol lowing table provides an overview of the range of func tions of the standard menu extended menu and product databanks The configuration menu is de scribed in the service guide Erroneous settings can lead to production setbacks damage to the machine and sys W N tem and can even cause work related acci EXPERTS dents Only specially trained and instructed per sonnel may alter the settings in the ex tended menu or access the product databanks CAUTION 2 3 CONTR
49. llowing 70 Calling up the extended menu 70 Applicator type APPL 70 7 Appendix EP cylinder dwell time APT1 71 Blowing time APT2 00ccceeeeeees z4 7 14 Factory settings 82 Delay time APT3 200 71 Fine tuning of the dwell time APT4 72 7 2 Product databanks 84 7 3 EC Declaration of Conformity 86 Il 1 1 1 GENERAL INFORMATION PLEASE OBSERVE THE FOLLOWING 1 1 1 Validity and applicability of this manual Contents The present manual refers exclusively to the ALS 380 Labeller and the high speed ALS 380 HS version The manual is to be referred to for correct operation and ad justment of the machine The prerequisites for operation and adjustment are proper installation and configuration of the machine For technical questions which are not addressed in this operating manual gt Refer to the Service Guide for the ALS 380 Labeller or gt consult the servicing technician of our sales partner The responsible servicing technician of our sales partner is at your disposal and particularly helpful with configuration settings and remedying malfunc tions Technical State Technical state as of 06 2005 Software versions ALS 380 6 1 ALS 380 HS Master 1 1 Slave 1 0 Avery Dennison reserves the right to implement modifications of structural parts compo nents and software
50. ly into its operating position Unwind unit drive defective experts Repair by servicing technician is required refer to a Service Guide The photoelectric sensor in the loop Reflective surface is dirty space does not actuate gt Clean the reflective surface q Use of very bright labels or experts Sensor potentiometer out of adjustment or Sensor defective Adjustment replacement by servicing technician is required refer to Service Guide 6 OPERATIONAL MALFUNCTIONS 6 2 ERROR MESSAGES Message Description Possible causes and remedies E 2 Label stop sensor does not detect Ribbon of labels does not run through the slot in the photoe the labels lectric sensor gt Check the ribbon guide at the label stop sensor Label roll empty or more than 3 labels missing gt Replace label roll as required Pressure roller not closed gt Swing back the pressure roller dispenser head and return it to its position pressing against the roller The pressure roller clicks neatly into its operating position Insufficient labelling speed The product pulls the label off of the base material gt Synchronise the labelling speed and product speed VE LO function Other options experts gt Manually adjust the sensitivity of the label stop sensor CONT gt Check the label stop position STOD gt Check the label distance setting LPIT gt Check to see whether the feed motor at the dis penser hea
51. make adjustments to the machine in chine vicinity accordance with this manual and with all due care CAUTION Danger of body part trapping and pinching at Protect against injuries that can result the dispensing edge due to products moving in the conveyor direction gt Never reach between the product and dis pensing edge of running or operation WARNING AN The machine is connected with the mains ready machines supply Contact with energised components gt During operation never remove or defeat can result in life endangering currents the purpose of protective guards that pre through the body as well as burns vent reaching into the machine gt Only put the machine into operation when installed in a correctly installed housing Protection against chemicals The housing may only be removed by trained personnel when the machine is I CAUTION de energised Operational materials such as cleaning from electrical current gt Pull out the mains power connection plug K agents or adhesive solvents may pose a from the socket before cleaning and health risk maintenance gt Rules work guidelines and safety regula The machine is not protected against tions issued by the manufacturer must splashing water absolutely be followed gt Maintain the machine in a dry condition gt Incase fluids penetrate into the machine interior immediately switch off the ma chine and disconnect or plug out from the mains power supply Not
52. nction press the ENTER key again Exit the extended menu gt Press the NEXT or PRIOR key until QUIT appears on the display gt Press the ENTER key This exits the extended menu The last active menu is active again If the machine is now to be operated by personnel who are not authorised to work in the extended menu gt Ensure that the standard menu is active 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 3 Position of second label POS2 If the products are to be given two labels Distance between the leading edges of the first and second label 58A In the extended menu Call up the POS2 function Set the desired distance Settings are possible in 0 1 mm steps minimum la bel length maximum 999 9 mm POS2 is not active if the value is set to 0 Confirm the setting using the ENTER key and exit the POS2 function gt gt Ra 4 4 4 Position of third label POS3 If the products are to be given three labels Distance between the leading edges of the second and third label 59A In the extended menu gt Call up the POS3 function gt Set the desired distance Settings are possible in 0 1 mm steps minimum la bel length maximum 999 9 mm POS3 is not active if the value is set to 0 gt Confirm the setting using the ENTER key and exit the POS3 function S 58 A Position of second label Distance between the leading edges of the first a
53. nd second label f 59 A Position of third label Distance between the leading edges of the second and third label 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 5 Speed ratio VERT Relationship between the dispensing speed and the conveyor belt speed Example 60 Circumferential labelling of a round prod uct The product simultaneously makes a linear move ment and a rotational movement In the extended menu gt Call up the VERT function The preset is 100 corresponds to a ratio of 1 1 gt Set the desired value Possible settings 80 to 1000 corresponds to 0 8 1 to 10 1 gt Confirm the value using the ENTER key and exit the VERT function Example 60 The rotational speed A is twice as great as the lin ear speed of the product B The dispensing speed must roughly correspond to the rotational speed gt Set the setting for VERT to 200 ratio 2 1 gt If necessary use the fine adjustment 60 Example The product simultaneously moves from left to right and rotates about its axis A Rotational speed B Linear speed conveyor belt speed ALS 4 4 SETTINGS IN THE EXTENDED MENU 4 4 6 Adjust the label stop sensor CONT Technology Automatic and manual adjustment The sensitivity of the label stop sensor must be adjust ed to match the transparency of the labels and the backing material In most applications it is possible to
54. ng the ENTER key and exit the function Press the FEED key A label is dispensed The leading edge of the next label should rest exact ly on the dispensing edge 64 Remove a single label from in front of the sensor 65 Press the FEED key A label is dispensed 66A The gap on the label ribbon should be automatically compensated for 66B The leading edge of the following label should rest exactly on the dispensing edge 66C After the check Check the label stop position STOD refer to page 42 64 The leading edge of the following label should rest on the dis pensing edge Fy 65 Remove a single label from in front of the sensor L L U A B Cc 66 After pressing the FEED key A A label is dispensed B The gap on the label ribbon should be automatically compen sated for C The feed stops the leading edge of the following label should rest on the dispensing edge 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 9 Product length PRDL A start signal can be prematurely triggered by the shape of the product or reflective surfaces In sucha case the product length must be manually set Example 67 If 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 sig nals without the PRDL function the product would be labelled several times With t
55. nveyor belt speeds gt If necessary correct the setting value for APT4 The greater the value for APT4 the farther forward the label is applied The smaller the value for APT4 the farther to the rear the label is applied 5 AFTER OPERATION 5 1 CARE AND CLEANING 5 1 1 Cleaning agents 5 1 2 Regular maintenance J Cleaning agents for rubber rollers The ALS380 labeller is designed to be mainte A Roller cleaner ordering code 98925 nance free Nevertheless to ensure long lasting and If other cleaning agents are used there is reliable operating results regular maintenance is re some risk of dissolving the rubber quired Cleaning agents for adhesive residues Label loosening spray Depending on operating conditions at least weekly gt Carry out the cleaning and maintenance work de Other cleaning agents scribed in the following Isopropyl alcohol CAUTION Isopropyl alcohol is flammable gt Keep cleaning agents and used rags away from open flames and other sourc es of ignition Isopropyl alcohol vapours can cause head aches nausea dizziness or eye irritation gt Only use it in well ventilated areas gt Do not ingest it Prolonged contact with the skin depletes the skin s natural oils which can lead to irrita tion gt Avoid contact with the skin if possible If you have sensitive skin wear gloves CAUTION Unsuitable cleaning agents can cause con siderable damage
56. o production POS MLAB setbacks damage to the machine and sys POS2 PDT VW N tem and can even cause work related acci k d dents POS3 PDWT Only qualified and specially trained per VELO EGRA sonnel or the responsible servicing tech _ STOD _ VERT nician are authorised to access the product databanks CONT APPL E SS APT1 LPIT APT2 PRDL APT3 P_S_ APT4 S S_ 4 OPERATION 4 3 PRODUCT DATABANKS Activating product databanks at switch on The menu Product databanks is only available if at least one product databank is created While switching on the machine press and hold the PRIOR key The product databank menu is activated The indicator with the last activated product databank 52 blinks Repeatedly press the NEXT or PRIOR key until the desired product databank is shown on the display Activate the product databank by pressing the ENTER key Once the label dispensing is started the settings of the activated product databank are adopted e The product databank menu is automatically 1 started when the machine is switched on if it was active before the last shut down of the ma chine If the machine is operated by personnel who are not authorised to work in the product databank menu gt Switch off the machine at the main switch gt Press and hold the NEXT key and switch the machine on again at the main switch The s
57. ockwise to retract the chucking wedge 13A in the unwinding spindle gt If there is still an old roll core on the unwinding spin dle remove the old roll core gt Completely push on the new label roll gt Rotate the knurled knob counter clockwise to se cure the label roll on the unwinding spindle Also for top labeller Also secure the label roll to the dancer arm in the axial direction gt Allow the dancer arm to lightly rest against the label roll and gt swing it approximately 1 cm over the unwinding spindle The dancer arm must not be allowed to touch the unwinding spindle gt Tighten the set screw at the guiding rod 13 New label roll on the unwinding spindle secured to the guiding rod on the side A Chucking wedge in the unwinding spindle B Knurled knob on the unwinding spindle C Guiding rod 3 PRIOR TO OPERATING 3 1 INSERT THE LABELLING MATERIAL 3 1 3 Threading the label ribbon Overview of the threading path diagram 14 Threading path diagram for label ribbon with the labels on the outside A Right hand version B Left hand version 15 Threading path diagram for label ribbon with the labels on the inside A Right hand version B Left hand version 3 PRIOR TO OPERATING 3 1 INSERT THE LABELLING MATERIAL Thread the label ribbon at the unwind unit gt gt Swing up the pressure roller 16B and the braking brush
58. ompensation This error is indicated if The dispensing speed is excessively fast at the trailing edge of the label Ifa printer is connected the device will print more than once 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 8 Distance from the label stop sensor to the dispensing edge E SS Correct specification of the distance between the la bel stop sensor and the dispensing edge is a prereq uisite for setting the label stop position STOD Set distance gt Adjust the distance between the label stop sensor and dispensing edge Round the measured value up to a whole number value in mm In the extended menu gt Call up the E SS function gt Input the distance value Settings are possible in 1 mm steps Minimum 12 mm Maximum 1000 mm A maximum of 15 labels can be located between the photoelectric sensor and the dispensing edge Confirm the value using the ENTER key and exit the function Check setting see next page The minimum setting depends on the dispens ing speed The greater the dispensing speed the great er the minimum distance If the minimum distance is not maintained the warning message W__7 appears 63 A Distance between the label stop sensor and dispensing edge 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU Check setting gt gt gt Call up the STOD function Set the value for STOD to 0 Confirm the value usi
59. or yN ee a experts belt is insufficient gt Increase the product distance gt For circumferential labelling Increase the rotation al speed y J The product triggers several start signals caused by experts reflections for example A gt Adjust the product length PRDL When using a printer the printing time is too long 7 N experts gt f possible decrease the printer dwell time PDWT gt Start printing process before label stop PDT 6 OPERATIONAL MALFUNCTIONS 6 1 WARNING MESSAGES Message Description Possible causes and remedies W_2 Memory errors CPU battery is discharged after a long shut down period of Factory settings are activated see the machine appendix gt Leave the machine switched on for some time to re charge the battery y If the accumulatorerror occurs frequently experts gt Have the CPU battery replaced by the responsible servicing technician Settings no longer available after software update 7 q n l experts Settings must be input again by a servicing techni cian refer to Service Guide W_3 Too many labels between label stop y Label stop sensor must be adjusted by servicing sensor and dispensing edge experts technician refer to Service Guide W_4 Dispensing speed is too high gt Reduce dispensing speed VELO if the warning This negatively affects position accu message is frequently displayed for long periods racy For automatic dispens
60. peed CONT 0035 Sensitivity of the label stop sensor E SS 0064 Distance between label stop sensor and dispensing edge 64 mm LPIT 1000 Label distance 100 0 mm PRDL AUTO Product length LPIT P_S_ LEDG Product sensor Triggered by leading edge S_S_ LEDG Label stop sensor Triggered by leading edge MLAB 0000 Machine stops as soon as a product is not labelled PDT 0000 Label stop Printer start PDWT 0000 Printer dwell time 0 0 s EGRA 0600 APSF compensation factor for RPM transmitter with 0 166 mm pulse TMOD OFF Tandem operation off 7 APPENDIX 7 1 FACTORY SETTINGS Function Value Explanation APPL DIR Applicator mode off APT1 0001 EP applicator dwell time 1 ms APT2 0001 EP applicator blow time 1 ms APT3 0000 EP applicator Delay of the signal air blow 0 ms APT4 0001 Applicator operation with APSF correction of the applicator dwell time 1 ms MDIR se mee oe Turning direction of all motors for right hand version OMOD ON Machine goes into online mode operation ready after switch on TAND 0000 Distance between product sensors during tandem operation 0 0 mm 1 SLEW 0100 Dispense speed during missing label compensation 100 m min 1 COMP ON Automatic label compensation activated 1 LABC 000 Label counter is reset to 0 APSF OFF Automatic dispensing speed switched off BAUD NONE PARI NONE SBIT aati Settings for data transmission to the serial inte
61. r changing the label roll see section Prior to operating chapter Insert the la belling material Insert the label roller 36 Prerequisites for reloading label material during operation A The label roll is empty on the first machine The machine is not running The end of the label material is still in the loop space The operator panel indicates W__5 B The second machine automatically takes over the labelling The operator panel indicates ON 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN Switching off Switch over the active machine On the operator panel of the active machine gt Press the FEED 37 key The indication on the operator panel changes from ON to BUSY until the machine stops The machine switches over to standby The opera tor panel indicates LOCK The other machine is activated Stopping operation On the operator panel of the active machine gt Press the ENTER key The machine stops the operator panel indicates OFF The other machine is activated On the operator panel of the now active machine The indication on the operator panel changes from LOCK to ON gt Press the ENTER key The machine stops the operator panel indicates OFF To resume operation gt On the machine that is to begin labelling first press the ENTER key The operator panel of this machine indicates ON gt On the other machine press the ENTER key
62. rations gt Adjust the photoelectric sensor using the CONT function gt Refer to chapter Operation Settings in the extended menu 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN 4 1 2 Labelling Prerequisites Label material is inserted Machine is switched on Material is initialised If OFF appears on the operator panel gt Press the ENTER 28 key until ON 29A is shown If ON appears on the operator panel 29A Zol ENTERkey The unwinding drive runs for a moment and fills the loop space with label ribbon 29B The dancer arm rewinding unit 29C points down ward The unwinding drive runs for a moment until the dancer arm points upward at an angle of approx 45 The machine is now ready for operation If no ON display appears on the operator pan el The machine is possibly in offline mode or one of the prerequisites for operation has not been met gt Instruct a qualified and authorised servicing technician to carry out the settings in the con figuration menu For further information refer to the service guide 29 Operation ready labeller 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN Start dispensing labels The conveyor belt starts up The first product reach es the product sensor photoelectric sensor 30 The product sensor sends a start signal The start signal from the product sensor
63. rective 89 336 EEC Low Voltage Directive 73 23 EEC Applicable Harmonized EN ISO 12100 2003 Safety of Machinery Standards in particular EN 294 1992 Safety of Machinery EN 61000 6 3 2001 Emission standard for residential commercial and light industrial environments EN 61 000 6 2 2001 Immunity for industrial environments EN 61 000 3 2 2000 Limits for harmonic current emissions EN 61000 3 3 1995 A1 2001 Limitation of voltage fluctuations and flicker Marla SK Markus Roderer General Manager Eching 19 July 2004 051790 Avery Dennison Deutschland GmbH Postfach 1163 85385 Eching Germany AVERY Telephone 49 8165 925 0 DENNISON http www machines averydennison com Link information to your product
64. rface 1 NUMB 0001 PRNT STAM Printer type used Heat transfer printer 1 79 Factory settings 1 Function in the configuration menu see Service Guide 7 APPENDIX 7 2 PRODUCT DATA BANKS Client Order Function Data bank PDO1 PD02 PD03 PD04 PD05 PD06 POS POS2 POS3 VELO STOD CONT E SS LPIT PRDL P_S_ S_S_ MLAB PDT PDWT EGRA VERT APPL APT1 APT2 APT3 APT4 Date Signature 7 APPENDIX 7 2 PRODUCT DATA BANKS Client Order Function Data bank PD07 PD08 PD09 PD10 PD11 POS POS2 POS3 VELO STOD CONT E SS LPIT PRDL P_S_ S_S_ MLAB PDT PDWT EGRA VERT APPL APT1 APT2 APT3 APT4 Date Signature 7 APPENDIX 7 3 EC DECLARATION OF CONFORMITY We the Avery Dennison Deutschland GmbH Ohmstrake 3 D 85386 Eching declare that we have designed and constructed the following designated machine in such a way that it complies with the basic safety and health requirements of the EC Directive Machine designation ALS 380 Machine type Label Dispenser Serial number Comprised of a running number 5 digits date code YY MM ending machine designation ALS380 Example 040060309 ALS380 Relevant EU directives Machinery Directive 98 37 EC EMC Di
65. roduct databanks 50 4 3 4 Deleting a product databank 51 4 4 Settings in the extended menu 52 44 1 Overview 2002 eee ees 52 4 4 2 Activating an extended menu 54 Please observe 2000 eee eees 54 Calling up Menu 2 eee 54 Call up function 20 54 Exit the extended menu 54 4 4 3 Position of second label POS2 55 4 4 4 Position of third label POS3 55 4 4 5 Speed ratio VERT 0 0 56 4 4 6 Adjust the label stop sensor CONT 57 Technology 2200000000 eee 57 Automatically adjusting the photoelectric SONSOF ws is hake eee ee Pe ed ee ee 57 Manually adjusting the sensor 58 4 4 7 Label distance LPIT 59 Check setting 0 0 0 00 59 4 4 8 Distance from the label stop sensor to the dis pensing edge E SS 60 Set distance 00200020000 60 Check setting 0 0 2 00 0 eee eee eee 61 4 4 9 Product length PRDL 62 4 4 10 Polarity of the product sensor P_S_ 63 4 4 11 Polarity of the label stop sensor S_S_ 63 4 4 12 Number of unlabelled products MLAB 64 4 4 13 Electronic transmission ratio of the RPM transmitter EGRA 64 4 4 14 Advance print start PDT 65 4 4 15 Printer dwell time PDWT 65 4 4 16 Tandem operation TMOD
66. se the material 33 Labelling 2 22 07 vateaaariinde KERERE 34 Prerequisites 0000 34 Start dispensing labels 35 Unwind unit 0 0002 36 Rawind Unites oiee Amii inehceda eee 36 Stop end the label dispensing 36 Tandem operation 37 Principle of operation 37 Prerequisites 000 0 e eee eee 38 Start dispensing labels 38 Reloading label material 39 Switching off 0 2000005 40 Setting and monitoring 41 Settings in the standard menu 41 OvervieW 0 200 0c 41 Calling up Menu 2 2 41 Call up function 2 05 41 Label stop position STOD 42 Dispensing speed VELO 43 Automatic dispensing speed optional 43 Label position on the product POS 44 Automatic material initialisation INIT 45 If errors OCCUP 1 2 2 2 2c eee eee 46 ALS 4 3 Product databanks 48 4 3 1 Functions 2 200005 48 4 3 2 Loading product data banks 48 Please observe 2000 eee eeee 48 Activating product databanks at switch on 49 Activating product databanks after switch on 49 4 3 3 Create save product databank 50 Prerequisites 00 eee eee 50 Saving the product databank 50 Documenting p
67. setting using the ENTER key and exit the VELO function Test the setting gt Remove the pressure roller unit optional at the dis pensing edge Start the system and only label one product The labelling speed is too low if the product pulls the label away from the backing material The labelling speed is too high if the label on the product has folds in it gt Automatic dispensing speed optional If the automatic dispensing speed APSF is activated Only display of the current speed using the VELO function Manual setting of the dispensing speed is not possi ble For further information on the APSF function see chapter Operation Automatic dispensing speed 43 Symbols on the operator panel keys A NEXT key B PRIOR key C ENTER key 44 VELO display on the operator panel 4 OPERATION 4 2 SETTING AND MONITORING 4 2 4 Label position on the product POS Distance between leading edge of the product and leading edge of the label 45A NO Prerequisites The label stop position STOD is correctly set A The dispensing speed VELO is correctly set gt Inthe standard menu press the NEXT 46A or PRIOR 46B key until POS 47 is displayed on the operator panel gt Call up the POS function by pressing the ENTER 46C key The distance is shown on the operator panel in mm gt Set the desired distance using the NEXT or
68. sing the NEXT or PRIOR l key Settings are possible in 0 1 mm steps Minimum 0 mm Maximum set label distance LPIT function A B c gt Confirm the setting using the ENTER key and exit the STOD function 41 Symbols on the operator panel keys A NEXT key B PRIOR key e fthe value for the STOD function shown on the C ENTER key 1 operator panel does not agree with the actual label stop position it is possible that the control system contains an erroneous value for the dis tance between the photoelectric sensor and the dispensing edge E_SS function in the extend ed menu STOD Q FEED a 42 STOD display on the operator panel 4 OPERATION 4 2 SETTING AND MONITORING 4 2 3 Dispensing speed VELO As a rule the labelling speed must correspond to the product speed Depending on the operating conditions the labelling speed can also be set somewhat higher in unique cases Prerequisites The label stop position STOD is correctly set gt Inthe standard menu press the NEXT 43A or PRIOR 43B key until VELO 44 is displayed on the operator panel Call up the VELO function by pressing the ENTER 43C key The current speed is displayed on the operator pan el in m min Change the labelling speed using the NEXT or PRI OR key Settings are permitted in steps of 0 1 m min Minimum 0 5 m min Maximum 80 m min ALS 380 HS to 100 m min Confirm the
69. t databank can now be deleted using the DEL function 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 1 Overview Function dis play Brief description ON The machine is ready for operation start dispensing labels OFF Stop end the label dispensing INIT Automatic material initialisation VELO Dispensing speed STOD Distance between dispensing edge and leading edge of the label POS Distance between leading edge of product product sensor and label POS 2 Distance between the leading edges of the first and second label on the same product POS 3 Distance between the leading edges of the second and third label on the same product VERT Relationship between the dispensing speed and the conveyor belt speed CONT Adjust the label stop sensor E SS Distance between label stop sensor and dispensing edge LPIT Label distance PRDL Product length P_S_ Polarity of the product sensor S S_ Polarity of the label stop sensor MLAB Allowable number of unlabelled products EGRA Compensation factor for RPM transmitter when operating with automatic dispensing speed adjustment not with ALS 380 HS see Service Guide TMOD Activate and deactivate tandem operation LOAD Loading product data banks SAVE Create and save a product data bank DEL Deleting a product databank QUIT Exit the extended menu 54 Functions in the extended menu of the ALS 380 4 OPERATION 4 4 SETTIN
70. tandard menu is activated Activating product databanks after switch on In gt gt gt the extended menu Call up the LOAD function The indicator with the last activated product data bank 53 blinks Repeatedly press the NEXT or PRIOR key until the desired product databank is shown on the display Activate the desired product databank by pressing the ENTER key Once the label dispensing is started the settings of the activated product databank are adopted Exit the extended menu using QUIT Q FEED n 52 Example Product databank PD01 FEED EP Q 53 Example Product databank PD01 4 OPERATION 4 3 PRODUCT DATABANKS 4 3 3 Create save product databank CAUTION Prerequisites Erroneous settings can lead to production setbacks damage to the machine and sys 7 N tem b A Only appropriately qualified and author ised personnel may create product data banks Settings in the following functions are updated POS MLAB POS2 PDT POS3 PDWT VELO EGRA STOD VERT CONT APPL ESS APT1 LPIT APT2 PRDL APT3 P_S_ APT4 SS_ 1 Setting the EGRA is required when operating the automatic dispensing speed adjustment APSF Saving the product databank In the extended menu Call up the SAVE function Select the desired product data
71. th automatic label compensation the trailing edge of the label passes the sensor 68B without automatic label compensa tion The function also allows the use of photoelectric sen sors with different polarities In the extended menu gt Call up the S_S_ function gt Set the desired polarity Set the LEDG Triggered by leading edge Set the TEDG Triggered by the trailing edge gt Confirm the setting using the ENTER key and exit the function a v U ae ae 3 S 1 A B 68 Examples for different polarities of the product sensor A The sensor sends a signal at the product s leading edge LEDG B The sensor sends a signal at the product s trailing edge TEDG 69 Examples for different polarities of the label stop sensor A The sensor sends a signal at the label s leading edge LEDG B The sensor sends a signal at the label s trailing edge TEDG 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 12 Number of unlabelled products MLAB If products do not get labelled the operator receives the warning message VV_0 at the operator panel If too many products in a row do not get labelled the machine stops The error message E_11 appears at the opera tor panel Using the MLAB function you can determine how many products in a row are allowed to be unla belled before the machine stops Example 70 MLAB is set to value 2
72. the order specific requirements ALS 1 2 SAFETY INSTRUCTIONS 1 2 2 Machine operating safety Appropriate use The ALS 380 labeller is a fully automatic machine for Protect against injuries that can result the application of self adhesive labels to products or from mechanical actions packages The machine is to be equipped by the oper ation planners with suitable safety devices so as to pro WARNING tect the operating personnel from possible Risk of injury due to moving or rapidly rotat endangerment e g pinching or entrapment of body ing parts parts due to reaching between product and dispensing gt The following regulations always apply edge gt Keep a distance from running machines Wear WARNING snug fitting clothing and hair nets Improper usage of the machine can lead to gt Even when the machine is idle maintain the area accidents material damage and loss of pro clear of movable parts if the possibility exists that duction the machine could start gt Only operate this machine in accordance gt Never lay tools or loose parts on the machine if the with information contained in this manu possibility exists that the machine could start al gt Switch off the machine before performing mechani gt Do not put the machine into operation cal adjustment tasks without the required safety equipment in gt Do not wear ties loose garments jewellery watch place es or similar articles on the body when in the ma gt Only
73. the LOCK indication remains in standby 4 OPERATION 4 1 ACTIVATION AND SHUT DOWN Reloading label material WARNING Risk of injury from the running conveyor line at the workplace Risk of pinching at the dis pensing edge gt Before reloading label material ensure that the machine in question does not start up unintentionally The operator panel must indicate the W__5 warning message Absolutely avoid coming into contact with the conveyor line and the moving products Only join the old and new label ribbons together in the unwinding section or in the loop space Never contact objects in the space near the dispensing edge If it is not possible to reload label material safely Stop operation see next page On the active machine the label material runs low 36 The machine stops even before the end of the label material reaches the dispensing edge The machine s display changes to W_5 The other machine is automatically activated The display of the currently active machine indicates ON On the idle machine display W__5 gt gt gt vu Remove the old roll core from the unwinding spool Leave the remainder of the label ribbon on the ma chine Insert new label roll Join the beginning of the label ribbon of the new la bel roll to the end of the old label ribbon with adhe sive Press the ENTER key The indication changes to LOCK The machine is now in standby e _ For procedure fo
74. the dispensing edge 2L The label separates from the backing material at the dispensing edge The drive roller unit in the dispensing head moves the respective ribbon for a label and then stops until the next product takes the label under the dispensing edge Label ribbon is continuously unwound at the unwind unit The loop acts as a buffer between the continuous ly operating unwind unit and the periodically operating label output The braking brushes keep the label ribbon taut From the dispensing head the empty backing material runs over several deflection rollers 20 to the mo tor driven spreaderrewinding unit 2M The multiple deflections with the spring loaded dancer arm 2N act as a buffer between the label output and the rewind unit The entire operation of the labeller is electronically con trolled and monitored If a malfunction occurs the con trol system sends a corresponding message to the operator If necessary the labelling operation is auto matically halted An electronic signal is issued at the same time The signal can be picked up by an external control system ALS 2 1 OVERVIEW 2 1 3 Technical data Characteristic values Dimensions Dispensing speed Dimensions ALS 380 0 5 m min to 80 m min Width 735 mm ALS 380 HS 0 5 m min to 100 m min Height 795 mm Depth 400 mm Stop accuracy at the dispensing edge 0 5mm Weight 7 ALS 380 50 kg Rewind unit Spr
75. through under the label stop sensor The LED illuminates if a label is under the photoe lectric sensor 61 The LED does not illuminate if only backing material is under the photoelectric sensor 4 OPERATION 4 4 SETTINGS IN THE EXTENDED MENU 4 4 7 Label distance LPIT The label distance is defined as 62 Label distance label length gap The shape of the labels or reflective surfaces can cause a false signal to be sent from the label stop sen sor In such a case the label distance must be manual ly set In the extended menu gt Call up the LPIT function gt Set the desired distance Settings are possible in 0 1 mm steps Minimum 5 mm 62 A Label distance Maximum 500 mm B Label length gt Confirm the value using the ENTER key and exit the C Gap function gt Press the FEED key to test the setting A single label is dispensed Check setting gt Press the FEED key If the setting is correct A single label is dispensed at a constant dispensing speed The label completely separates from the backing material and no wrinkling occurs If the setting value for LPIT is too large 2 labels are dispensed If the setting value for LPIT is too small A single label is dispensed Because the value for LPIT is too small the control unit prematurely anticipates a signal from the label stop sensor The missing signal triggers automatic label c
76. tting 600 corresponds to resolutions from 0 10 0 154 mm pulse gt Call up the EGRA function in the extended menu gt Input the calculated setting value and exit the EGRA function e The setting of the electronic transmission ratio 1 affects the dispensing speed The smaller the EGRA compensation factor the greater the dispensing speed When the EGRA has a low setting value and a high conveyor belt speed the allowable dispensing speed can be exceeded Ifthe dispensing speed is too great the warning message W__4 appears Test the setting gt Remove the pressure roller unit at the dispensing edge gt Start the system The labelling speed is too low if the product pulls the label away from the backing material The labelling speed is too high if the label on the product has folds in it 4 OPERATION 4 6 APPLICATOR OPTIONAL 4 6 1 Principle of operation If direct labelling from the dispensing edge is not possi ble the labeller can be equipped with an applicator In applicator mode the applicator takes the label from the dispensing edge and carries it to the product The labeller can be equipped with various applicators depending on the need The following are possible Air Stream Applicator pneumatic applicator Using suction the applicator takes the label from the dispensing edge transports it until it is directly in front of the product and then blows the label onto
77. ue the machine stops Label supply lfno more labels arrive at the label stop sensor 9A 10A the machine stops and sends a signal to the 9 A Label stop sensor output to the system controller B The product sensor sends a signal when the product has Install roll diameter control optional reached the dispensing edge If the diameter of the label roll on the unwinding C Label roll on the unwinding spool spool 9C becomes too small the control system sends a warning message and a signal to the output to the system controller The diameter at which the signal will be sent can be set by servicing techni cians If errors occur If a malfunction occurs the control system sends a cor responding message to the operator If necessary the labelling operation is automatically halted The ma chine simultaneously sends a signal to the system con troller 10 Backing material with a label under the label stop sensor A 3 PRIOR TO OPERATING 3 1 1 Prerequisites The label dispenser is switched off at the main 11A switch Verify flawless functioning of the safety equipment Check machine for visible damage Any discovered deficiency is to be reported immediately Non required materials and objects are to be re moved from the working area of the machine Make sure that only persons authorised to work on the machine are within the working area of the ma chine Use required personal saf
78. xially with the setting rings Tighten the knurled thumb screws 21 Pressure roller centrally aligned on the label ribbon 3 PRIOR TO OPERATING 3 2 MECHANICAL SETTINGS 3 2 4 Adjust the pressure roller unit optional at the dispensing edge Depending on the area of application the labeller can be equipped with an additional pressure roller unit 22A at the dispensing edge The most favourable positioning of the pressure roller unit differs depending on the application For information on adjusting the pressure roller unit the responsible servicing technician is at your disposal To set the position of the pressure roller unit relative to the label ribbon gt Loosen the fastening screws 22B gt Adjust the pressure roller gt Tighten the fastening screws 22 Optional pressure roller unit 3 PRIOR TO OPERATING 3 2 MECHANICAL SETTINGS 3 2 5 Adjust optional the position of the dispensing edge Adjusting vertically Coarse adjustment gt Open the central lock 23B gt Hold the dispenser head firmly and open the lower lock 23C gt Slide the dispenser head to the desired height and tighten the lock 23C Fine adjustment gt Open the upper lock 23A gt Rotate the spindle 23D clockwise to move the dis pensing edge downward or rotate the spindle coun ter clockwise to move the dispensing edge upward gt Tighten the lock 23A
79. xperts reflections for example b gt Adjust the product length PRDL function 6 OPERATIONAL MALFUNCTIONS 6 2 ERROR MESSAGES Message Description Possible causes and remedies E 15 Short circuit A check of the connections and output signals by or EXPERTS servicing technicians is required refer to the Service Overload of outputs from CN10 Guide ER U Software error gt Press the ENTER key gt Make note of all the information that is displayed on the ER Software error control panel ER D Software error gt Make note of what happened before the error occurred ER T Software error gt Notify the responsible servicing technician EXPERTS ER A Software error 7 APPENDIX 7 1 FACTORY SETTINGS r In the case of a memory error The message W__2 orE_12 appears on the 1 operator panel All databanks are deleted The settings of the machine are reset to fac tory settings 79 Function Value Explanation VELO 0500 Labelling speed 50 0 m min STOD 0000 Distance between dispensing edge and label s leading edge 0 0 mm POS 0500 Distance between leading edge of product and label 50 0 mm POS 2 0000 Multiple labelling Distance between the leading edges of the first and second label 0 mm POS 3 0000 Multiple labelling Distance between the leading edges of the second and third label 0 mm VERT 0100 Dispensing speed conveyor belt s

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