Avery Dennison ALS 230 manual

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Operators Manual ALS 230 Release 11/05 Page i Contents Contents 1. Important Notes ........................................................................................................ 4 1.1 Overview ....................................................................................................................... ................ 4 1.1.1 Ma[...]

Operators Manual ALS 230 Release 11/05 Page ii Contents 4. Operatio n ............................................................................................................... 23 4.1 Safety reco mmendation .......................................................................................................... .... 23 4.2 Inserting labe l ma[...]

Operators Manual ALS 230 Release 11/05 Page iii Contents 8.4 EMI ............................................................................................................................ ................. 66 8.5 Electronic diagrams ............................................................................................................ ......[...]

Operators Manual ALS 230 Release 11/05 Page 4 Important Notes 1. Important Notes 1.1 Overview The AVERY ALS 230 is a fully automatic labelle r. Handling is very easy and can be learned with a minimum of training. For operation, only a few adjustments are necessary. The machine is controlled by a microprocessor and because of its programmable functi[...]

Operators Manual ALS 230 Release 11/05 Page 5 Important Notes Avery Dennison Corporation is given or imp lied. All other brand and product names are the trademark of their respective owners. 1.2 Safety 1.2.1 General Safety Notes In order to avoid any risk of injury due to squeezing between the fixed dispensing edge and the passing product, it may b[...]

Operators Manual ALS 230 Release 11/05 Page 6 Important Notes 1.2.3 Operator’s duty of care The machine was designed and constructed taking into account a hazard analysis and after careful selection of the harmonised standards to be observed, as well as other technical specifications. Thus, it corresponds to the state of the art and allows the hi[...]

Operators Manual ALS 230 Release 11/05 Page 7 Important Notes 1.2.4 Concrete security regul ations and symbols used In the following operating instructions, concrete security regulations are indicated in order to point out the remaining risks which cannot be avoided when operating the machine. These remaining risks include danger to • Persons •[...]

Operators Manual ALS 230 Release 11/05 Page 8 Important Notes 1.2.5 Security measures during normal operation The machine may only be operated by trained and authorised persons who are familiar with the operating instructions and are able to work in accordance with it! • Before starting the machine, check and make sure that • only authorised pe[...]

Operators Manual ALS 230 Release 11/05 Page 9 Important Notes 1.2.7 Work on the electrical equipment Repair work on the electrical equipment of the machine may only be performed by a trained electrician! Electrical equipment must be checked on a regular basis! Loose connections must be fixed again! Exchange damaged lines/cables immediately! Always [...]

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Operators Manual ALS 230 Release 11/05 Page 11 Description 2. Description CAUTION! - The machine is connected to mains. Only authorised personnel may open the cover. Operation without this cover is not allowed. This chapter explains the structure and the function of the labeller. The expressions used are explained here. 2.1 Mechanics The machine is[...]

Operators Manual ALS 230 Release 11/05 Page 12 Description Figure 1 Dispensing mechanics At the dispensing edge (010) the label is separat ed from the backing paper. By means of a soft (005) roller the label is applied on to the product. Roller (012) makes sure that the material is always guided properly around the dispensing edge. Drive roller (00[...]

Operators Manual ALS 230 Release 11/05 Page 13 Description Dispensing is only possible when the handle (015) is in the closed position. Via the deviator roller (016) the backing paper is guided to the rewind mandrel (017). The cone between the 4 pins can be pulled out to allow the reward backing paper to b e removed. Except for the drive roller (00[...]

Operators Manual ALS 230 Release 11/05 Page 14 Description PRIOR: This key moves up the menu (prior function) or increases the value of a parameter. If the up arrow key is pressed and held as the machine is turned on the product menu is selected. NEXT: This key moves down the menu (next function) or decreases the value of a parameter. If the down a[...]

Operators Manual ALS 230 Release 11/05 Page 15 Description 2.3 Plug board The plug board is shown in Figure 3. Beside the mains switch and the mains cable socket there are some more holes for optional functions. Standard execution in this machine is on e I/O plug prepared for the product sensor. The connection of the other plugs is described in cha[...]

Operators Manual ALS 230 Release 11/05 Page 16 Description[...]

Operators Manual ALS 230 Release 11/05 Page 17 Preparing the machine 3. Preparing the machine In this chapter you will learn how to install and adjust the labeller. After this step ha s been completed you will be ready to learn how the labeller's parameters can be adjusted to suit your particular production requirements. 1.1 Installation 1.1.1[...]

Operators Manual ALS 230 Release 11/05 Page 18 Preparing the machine 1.2 Prepare dispensing 1.2.1 Insert material Insert your label material in the machine to follow the instructions in the chapter Operation / Threading. 1.2.2 Define label data For correct dispenser operation, you have to tell the machine the length of the label and adjust the labe[...]

Operators Manual ALS 230 Release 11/05 Page 19 Preparing the machine Setting LPIT manually To initialise labels with cut outs such as the one shown below - the "LPIT" parameter should be used to enter the label pitch of the label web. Sens or si gnal s L abel sen sor LPI T real le adin g edge of la bel Figure 4 Definition of LPIT All othe[...]

Operators Manual ALS 230 Release 11/05 Page 20 Preparing the machine A mechanical sensor is limited in the speed. The bounce at the label edges produces wrong signals. There is optional a capacitive label sensor available (Leuze GK14/24L). Adjustment of the sensor is carried out as follows (Figure 5): 1. Set sensitivity to maximum by turning the Po[...]

Operators Manual ALS 230 Release 11/05 Page 21 Preparing the machine With a L-dispensing the adjustment is done by move the tail sheaves behind the dispensing edge. 3.3 Adjust dispense function For an operation without any trouble and high label accuracy, tree adjustments are required: • Label position on the dispensing edge: stop position • Di[...]

Operators Manual ALS 230 Release 11/05 Page 22 Preparing the machine 3.3.3 Automatic dispensing speed (APSF) With a connected rotary encoder, the dispensing speed follow s the measured product speed. To adjust the speed use the EGRA function located in the extended standard menu. The measured speed will be displayed in the VELO function. Do the adj[...]

Operators Manual ALS 230 Release 11/05 Page 23 Operation 4. Operation This chapter describes the operation of the machine. 4.1 Safety recommendation CAUTION! y Before connections to the mains check the correct voltage selection. y Use only original spare parts for service. y Open of the cover is only allowed authorised personal. y Handling of the m[...]

Operators Manual ALS 230 Release 11/05 Page 24 Operation 4.2 Inserting label material Attention: • Before threading the new material, the waste paper should be removed. CAUTION! - Isertion/exchange of material should be carried out only by especially instructed personal. Threading of the label material is shown down below on the threading diagram[...]

Operators Manual ALS 230 Release 11/05 Page 25 Operation 4.3 Initialise new label material The machine requires data of the label material in use i.e. label length a nd opacity of the label and backing material. In most cases, those parameters can be scanned during automatic initialisation. This is not always possible. During initialisation, the ma[...]

Operators Manual ALS 230 Release 11/05 Page 26 Operation 4.4 Control of dispense unit 4.4.1 Dispenser Menu selection Turning on the mains switch and at the same time pressing one of the panel keys, you may select between several options: PANEL KEY & mains switch Function Display message FEED Material initialisation INIT NEXT FUNCTION Standard m[...]

Operators Manual ALS 230 Release 11/05 Page 27 Operation y Error display: If the display shows e.g. E__XX, the dispenser has recognised an error. A warning is shown by W_XX. As soon as the error has been corrected, you may erase the message by pressing the key ENTER and you will get back to the status the machine was in before the error was indicat[...]

Operators Manual ALS 230 Release 11/05 Page 28 Operation pressing the key PRIOR the value is increased, i.e. the label is put on later. By pressing the key NEXT FUNCTION the value is decreased and the label is p ut on earlier. The labelling position is also changed by variation of the pro duct speed. In this case first control you product speed and[...]

Operators Manual ALS 230 Release 11/05 Page 29 Operation Figure 9 Stop position Dispense speed __________________________________________________ VELO The speed value VELO displays the dispensing speed in 0.1 m/min. The product conveyor speed has to be constant to assure accurate labelling. A cha nge of the product speed causes a different position[...]

Operators Manual ALS 230 Release 11/05 Page 30 Operation If you want to switch to another product, select the respectiv e product number by pressing NEXT and PRIOR, then press ENTER. Now the new product data are activated. To change the labelling parameters you can call t he extended menu. After leaving this menu, your product data will be automati[...]

Operators Manual ALS 230 Release 11/05 Page 31 Menu structure 5. Menu structure The touch panel keys or the optional interface can change labeller parameters. The la st entered parameters are the actual ones the machine works with. Programming via the interface is described in chapter Serial interface. There are 2 levels for parameter adjustments. [...]

Operators Manual ALS 230 Release 11/05 Page 32 Menu structure • Power On at power on + at power on at power on or + CODE CODE Standard menu Extended menu Product menu Configuration INIT/ON/ OFF INIT/ON/OFF INIT/ON/OFF  Direct LPIT PD01 DTST INIT/ON/OFF CONT PD02 P_S_ POS SENS PD03 MACH STOD STOD PD04 MDIR VELO PRDL PD05 MLAB  POS PD06 APSF [...]

Operators Manual ALS 230 Release 11/05 Page 33 Menu structure 5.1 Standard menu Usually this menu is used for labelling. A ll important parameters can be changed while the machine is running. After turning power on, the standard menu is active, unless the p roduct menu was on before the machine was switched off. If the product menu is active and yo[...]

Operators Manual ALS 230 Release 11/05 Page 34 Menu structure Label position ____________________________________________________ POS Function: The start position POS defines when the labelling should take place, after the product has passed the product sensor. Changing the value for POS changes the applied label position on the product. Only avail[...]

Operators Manual ALS 230 Release 11/05 Page 35 Menu structure 5.2 Extended standard menu The extended standard menu offers additional parameters you may use in your application. On quitting this menu the current parameter settings are stored in memory. Further changes are also written into memory. As long as this menu is active, no labelling is pos[...]

Operators Manual ALS 230 Release 11/05 Page 36 Menu structure Display Function Data value PDT Printer dwell time Printer hold time (is 50% PDT) OFF - 1000ms SAVE Store data in the product data bank PD01 ... PD09 LOAD Load data from a product data bank PD01 ... PD09 QUIT Leave the extended standard menu standard menu Label pitch ____________________[...]

Operators Manual ALS 230 Release 11/05 Page 37 Menu structure Stop position ___________________________________________________ STOD Function: Stop position of the label at the dispensing edge. Available: Always Range: 0.0 .... 200.0 mm Product length ___________________________________________________ PRDL Function: The product length avoids multi[...]

Operators Manual ALS 230 Release 11/05 Page 38 Menu structure Start delay ______________________________________________________ STAD Function: Delay time for the dispensing by means of an applicator after the product has passed the product sensor. This value influences the position of the label on the product. Only available if applicator is used.[...]

Operators Manual ALS 230 Release 11/05 Page 39 Menu structure Blow on time_____________________________________________________ APT2 Function: Only used when an applicator is necessary . It defines for how long the label is blown onto the product. Available only with applicator. Range: 1 ... 7500 ms Restart delay ___________________________________[...]

Operators Manual ALS 230 Release 11/05 Page 40 Menu structure End of air stream signal ___________________________________________ ASTP This parameter determines how long the air stream signal will remain active after the label dispense has finished. Valid in all modes (direct dispense, applicator, AP SF and fixed-speed). Printer dwell time _______[...]

Operators Manual ALS 230 Release 11/05 Page 41 Menu structure 5.3 Product menu If parameters have to be changed because of different products and labels, the product menu can be used. The machine offers a data bank in which 14 sets of data ca n be stored. If you want to switch to a particular product, select one of the product numbers by pressing N[...]

Operators Manual ALS 230 Release 11/05 Page 42 Menu structure[...]

Operators Manual ALS 230 Release 11/05 Page 43 Configuration 6. Configuration Adjustments in the configuration menu are necessary during installation of the machine only. In the configuration menu , the required optional functions ca n be selected. Some service support functions in the configuration menu will be useful for the service staff. Possib[...]

Operators Manual ALS 230 Release 11/05 Page 44 Configuration 6.1 Handling the menu The menu structure is shown in the following table. By means of the key PRIOR you switch to the prior function, and with the key NEXT to the next following function in the menu. If you press the key ENTER the current parameter value of a function is shown. The curren[...]

Operators Manual ALS 230 Release 11/05 Page 45 Configuration 6.2 Menu functions The menu functions are explained in detail here. Permanent test ___________________________________________________ DTST The permanent test makes a test run without using labels. In the display the numbers of dispense cycles is shown (see description LABC). Immediately [...]

Operators Manual ALS 230 Release 11/05 Page 46 Configuration With this function, you can decide how to react: NONE Do nothing. The unlabeled product will be detected later in t he line. WARN Set the warning output and displays W__0. The production continued. ERR1 Set the error output to stop the production line immediately and display E_10. ERR2 Th[...]

Operators Manual ALS 230 Release 11/05 Page 47 Configuration Additional functions in the standard menu Depending on which parameter has been defined under APPL different menu functions are shown in the standard menu. If an applicator is used additional times BLOW and STAD for controlling the applicator cycling are available. Input and sensor check [...]

Operators Manual ALS 230 Release 11/05 Page 48 Configuration 6 = terminal 20 = ERROR 7 = terminal 31 = READY 8 = terminal 32 = ODC_OUT / HORI_CYL Adjustment resetting ______________________________________________ FACT This menu point sets all parameters back to the factory values. All parameters will be reset, so please note all your adjustments b[...]

Operators Manual ALS 230 Release 11/05 Page 49 Configuration Number of data bits _______________________________________________ DBIT The function is only visible if a baudrate is select ed. With this function you can select between 7 or 8 data bit protocols. Factory adjustment: 8BIT Recycle (simulates max la bels/min) _____________________________[...]

Operators Manual ALS 230 Release 11/05 Page 50 Configuration Note: Modified parameter values are only stored if the menu is left by using the QUIT function. If the power is switched off before leaving the menu by quit all modifications are lost .[...]

Operators Manual ALS 230 Release 11/05 Page 51 Serial interface 7. Serial interface The machine has a serial interface according to the standard RS232C. Via this interface parameters can be adjusted. All received commands are tested for syntax and legal value range. Invalid commands and parameters are ignored. An error message is not given in this [...]

Operators Manual ALS 230 Release 11/05 Page 52 Serial interface 7.2 Interface commands The below described commands will change one of the labelling parameter. The values are not stored and will be lost when turning off power. If the sequence nnnn is replaced by the character "?" then the current value of that parameter will be returned b[...]

Operators Manual ALS 230 Release 11/05 Page 53 Serial interface Command Description Range #!MDIRnnnn Motor direction 0000 Right --- > 0001 Left < --- #!MLABnnnn Missing label error 0000 NONE 0001 Warning 0002 Error 1 0003 Error 2 #!PDT nnnn Print dwell time 0001 – 1000 ms 0000 printer off #!PHT nnnn Printer hold time 0001 – 7500 ms #!POS_[...]

Operators Manual ALS 230 Release 11/05 Page 54 Serial interface #!SR__ The machine is set to on. The product sensor is enabled a nd labelling can restart. For a full automatic operation, the following procedure in case of an error is required: • #!ERRF Request error • #!CLRE Clear error message after fixing the error. The labeller shows „INIT[...]

Operators Manual ALS 230 Release 11/05 Page 55 Connections and signals 8. Connections and signals This machine has a number of inputs to connect sensor’s and a control. Outputs are available for applicators, a printer and other purposes. 8.1 Output signals This machine has eight outputs, which switch the output from open circuit to + 24V. The max[...]

Operators Manual ALS 230 Release 11/05 Page 56 Connections and signals 8.2 Applicator modes The machine is able to dispense the label direct on the passing product. There is also the possibility to drive without any external control a wide range of applicators. 8.2.1 Signals for direct dispense For direct dispensing the airstream signal can be used[...]

Operators Manual ALS 230 Release 11/05 Page 57 Connections and signals 8.2.2 Control signals for the ASA applicator For controlling an air stream applicator the signals air- stream and blow on are nece ssary. The time period APT2 defines how long the blow on signal is active. After labelling the product and the time period of APT3 a new label will [...]

Operators Manual ALS 230 Release 11/05 Page 58 Connections and signals 8.2.3 Signals for the EP applicator For controlling the applicator the signals air st ream, cylinder valve and blow on are necessary. After a product signal has occurred the labelling cylinder valve is switched active after the delay STAD. However if at this time the applicator [...]

Operators Manual ALS 230 Release 11/05 Page 59 Connections and signals 8.2.4 Applicator connector The applicator connection is done via a 15 pole D-sub connector common to other machines. Figure 13 Applicator connector[...]

Operators Manual ALS 230 Release 11/05 Page 60 Connections and signals 8.3 Input signals This machine (dispenser) is provided with photo coupled inputs for: y the product sensor signal y an inhibit signal for inhibiting labelling y a signal from an OD control which shows the end of the material roll. y a signal from an automatic product speed follo[...]

Operators Manual ALS 230 Release 11/05 Page 61 Connections and signals 8.3.1 Product sensor The product sensor starts the labelling. The source of the signal could be a optical sensor, a switch or a signal from a PLC. The time between start signal and start of dispensing (adjusted with POS) should be as small as possible. Thi s means that an optica[...]

Operators Manual ALS 230 Release 11/05 Page 62 Connections and signals 8.3.2 OD Control sensor Optional an OD control could be mounted to control the label roll. If the label material is nearly empty the sensor gives an signal. A warning message and an output signal inform the personal that in the next time the material has to be changed. +24V GND [...]

Operators Manual ALS 230 Release 11/05 Page 63 Connections and signals 8.3.3 APSF sensor For the APSF function (Automatic speed follower) a rotary encoder has to be installed. For optimum labelling accuracy the rotary encoder s hould be selected so that it produces one pulse for every 0.125 mm of product movement. The connection of the encoder shou[...]

Operators Manual ALS 230 Release 11/05 Page 64 Connections and signals 8.3.4 Control signals An optional connector could be installed for integration of the machine in the line co ntrol. 5 9 4 8 3 7 2 6 1 5 9 4 8 3 7 2 6 1 CN 33 re d gr een black s c hw ar z ro t gr ün +24 Volt +24 Volt Gr ound M as s e W ar ning output War naus gang Er r or outpu[...]

Operators Manual ALS 230 Release 11/05 Page 65 Connections and signals l Figure 22 Internal I/O connector[...]

Operators Manual ALS 230 Release 11/05 Page 66 Connections and signals 8.4 EMI To protect the machines against electrical noise and to pro tect production of electrical noise you have to follow this rules: Rule 1 All metallic parts must have a good and plane contact (no lacquer, aluminium oxide is an isolator). Use scratch washers. Rule 2 Signal li[...]

Operators Manual ALS 230 Release 11/05 Page 67 Connections and signals 8.5 Electronic diagrams Figure 23 Wiring diagram[...]

Operators Manual ALS 230 Release 11/05 Page 68 Connections and signals Figure 24 Layout dispenser el ectronic b oard[...]

Operators Manual ALS 230 Release 11/05 Page 69 Connections and signals LED V ol tage Ready LED Overtemperature 100% on Short circuit 25% on / 75% off Both 75% on / 25% of f + Dire c tion - Direction - NC + NC - Clo c k Read y Col le ctor Ready Emitter 48V AC 48V AC Phase1 B Phase1A 800 400 Resolutio n Figure 25 Layout stepper mot or driver The jump[...]

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Operators Manual ALS 230 Release 11/05 Page 71 Errors and warnings 9. Errors and warnings The software checks during the labelling permanently, if the machine runs under normal operation. If labelling is not possible, the display shows a message e.g. E__0. If the labelling can be continued, but a problem has occurred or may occur, the display shows[...]

Operators Manual ALS 230 Release 11/05 Page 72 Errors and warnings Message Meaning How to solve to the factory adjustment. E__4 Check sum of the labelling data is wrong. Labelling Parameters are set to the factory adjustment. All labelling parameter have to be adjusted again E__5 10V supply voltage for label sensor low. Short circuit in label senso[...]

Operators Manual ALS 230 Release 11/05 Page 73 Errors and warnings 9.2 Dispenser warnings In case of a warning message the relevant output is switched. The signal can be used for interconnection with an external machine control. Warning W__5 activates only the special OD warn output. Message Meaning How to solve W__0 New start signal from product s[...]

Operators Manual ALS 230 Release 11/05 Page 74 Errors and warnings[...]

Operators Manual ALS 230 Release 11/05 Page 75 Technical Specification 10. Technical Specification The following data are maximum values. Depending on label material, operation environment and labelling condition the real value could be lower. 10.1 Technical Information Description Details Label width: incl. Backing paper 10 mm ... 100 mm Label len[...]

Operators Manual ALS 230 Release 11/05 Page 76 Technical Specification Description Details Power consumption 300 VA Mains voltage 100V~, 115V~, 200V~ and 230V~ 50/60Hz (6.3A for 110V else 3.15A), +5%- 10% 10.2 Application specification The labeller is designed and built for automatic applies of self-adhesive labels. 10.3 APSF- Sensor Specification [...]

Operators Manual ALS 230 Release 11/05 Page 77 Technical Specification 10.4 Performance The following tables show the maximal theoretically labels per minute rate. Tolerances in product speed, label and product dimensions reduce the label rate. The tables are valid for direct dispensing (without applicator and printer) . For critical applications, [...]

Operators Manual ALS 230 Release 11/05 Page 78 Technical Specification 10.4.2 Dispensing speed reached w h ile dispensing certain label length Dispensing speed reached in reference to label length dispensed 0 5 10 15 20 25 30 35 0, 3 75 1,5 2, 6 25 3 ,75 4,875 6 7 , 125 8,25 9 , 375 10,5 11 ,6 3 1 2 ,75 13 ,8 8 15 16 ,1 3 Label length (mm) Dispensi[...]

Operators Manual ALS 230 Release 11/05 Page 79 Technical Specification Note: As in most real labelling environments the products will have a spacing of at least 1cm the actual labelling rate can simply be calculated by dividing the product pitch into the conveyor speed. Product length = 100 mm; Product distance = 50 mm; Conveyor speed = 20 m/min La[...]

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Operators Manual ALS 230 Release 11/2005 Page 81 11 Adjustment 11. Adjustment Function Factory Application P_S_ LEDG MACH 230 MDIR Å RAMP FAST MLAB WARN COMP ON APSF OFF APPL DIR BAUD NONE PARI NO SBIT 2BIT DBIT 8BIT DIST 76.0 mm PHT 1 SLEW FAST[...]

Operators Manual ALS 230 Release 11/2005 Page 82 11 Adjustment Function Factory PD01 PD02 PD03 PD04 POS(STAD) 100.0 mm VELO 30.0 m/min STOD 76.0 mm BLOW(APT2) 1 ms LPIT AUTO CONT AUTO PRDL AUTO EGRA 500 APT1 200 ms APT3 0 ms APOS 0 ASTP 0 PDT OFF Function PD05 PD06 PD07 PD08 PD09 POS(STAD) VELO S T O D BLOW(APT2) L P I T CONT PRDL E G R A APT1 APT3[...]

12. Index A applicator ........................................... 53, 55 Applicator ................................................. 42 APSF ........................................... 40, 42, 58 ASA.......................................................... 53 Automatic product speed follower....... Siehe APSF C capacitve label ..................[...]