Avery 256 manual

ALS 204 /206 256 O PERATING INSTRUCTIONS Label Dispenser Edition 04/2007[...]

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i C ONTENTS ALS 20x 256 GB 1 Please note 1.1 General notes 1.1.1 Validity and binding effect of this ma nual . . . . 1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Technical status . . . . . . . . . . . . . . . . . . . . . . . . . 1 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Manufacturer . [...]

ii C ONTENTS ALS 20x 256 GB > CPU BOARD DATA submenu . . . . . . . . . . . . 28 > DISPLAY DATA submenu . . . . . . . . . . . . . . . 28 > CF CARD SLOT submenu . . . . . . . . . . . . . . . 28 > PERIPHERAL DATA submenu . . . . . . . . . . . 28 >MEMORY DATA submenu . . . . . . . . . . . . . . . 28 3 Before operation 3.1 Electrical conn[...]

1 C ONTENTS 1.1 G ENERAL NOTES ALS 20x 256 GB 1.1.1 Validity and binding ef fect of this manual Contents The present manu al refers e xclusively to the ALS 204, ALS 206 and ALS 2 56 label dispensers. It is written for the purpo se of ensuri ng profession al usage and calibration of the unit. Prerequisite s for the use and adjustment are the profess[...]

2 C ONTENTS 1.1 G ENERAL NOTES ALS 20x 256 GB 1.1.2 Illustrations and descriptions Signs and symbols Various inform at ion type s ar e ind ica te d in diff er en t ways within the document in order to simplify readability and compr ehension. Sentences starting with an arrow are instructions and guidelines. £ Perform the instructions one after an o[...]

3 C ONTENTS 1.2 S AFETY INSTRUCTIONS ALS 20x 256 GB 1.2.1 Information and qualifications Follow the instructions WARNING! Safe and efficient ope rat ion of the label dispenser can only be guara nteed if you observe all nec essary information. Product liabilit y an d warra nty cl aims can only be as serted if the unit was opera ted in accordance wit[...]

4 C ONTENTS 1.2 S AFETY INSTRUCTIONS ALS 20x 256 GB 1.2.2 Operational safety of the unit Proper usage The ALS 20x Label Dispenser is a fully automatic unit for attaching self-adhesive labels to produ cts or packaging. The company oper ating the unit must install it with suitable equipment to protect operati ng personnel from dan ger; for examp le, [...]

5 C ONTENTS 1.2 S AFETY INSTRUCTIONS ALS 20x 256 GB Protection against injuries by mechanical action WARNING! Risk of injury due to moving and rapidly rotating parts! – Long hair, loose jewellery, long slee ves, and so on are not permissible when using the unit. £ Sufficient protective clothing must be worn. £ Keep moving parts free from obstru[...]

6 C ONTENTS 1.2 S AFETY INSTRUCTIONS ALS 20x 256 GB 1.2.3 Before beginning production Due diligence of th e operating company and the service technician £ Ensure that the following pr erequisites ar e fulfilled in accordance with the service instructions: – The machine is installed pr operly and c onfigured in accordance with the guidelines. –[...]

7 C ONTENTS 1.2 S AFETY INSTRUCTIONS ALS 20x 256 GB 1.2.4 Safety notes on the unit CAUTION! Warning notes on the un it represent important informatio n for t he personnel using it. £ Do not remove warning not es. £ Replace any missing or illegible warnings. The ‘Pinch Point’ warning [1] note warns you of the danger pose d by the machine’ s [...]

8 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB 2.1.1 Components [3] ALS 204 Label Dispenser (right-handed version) A CD E F H I J K L M N O B G 2 P RODUCT DESCRIPTI ON 2.1 OVERV IEW[...]

9 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB A Control panel – For sending command s to the device and for displaying operating states and error messages. – An optional external control pa ne l can also be connected to the device. B Dancer arm – Keeps the label materi al stretched tight evenly. – Arrests the rotation of t he material roll if te[...]

10 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB 2.1.2 Control panel Operating LED Lights up green when the device is switched on. Error LED Lights up red when an erro r occurs. LCD display – Displays functions, configured values, opera t ing states and error me ssages. – What is displayed at any one time de pends on the operating status of the device[...]

11 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB 2.1.3 Connection arrangement Connections on the back of the device [5] Connections on the back of the device (ALS 20x): A Power supply connection B Network connection (Ethernet 10/100) C Serial interface (RS232) D Connection for external control panel (RS485) E Plug-in card slot (CompactFlash car d s) F USB[...]

12 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB Sensor connections [7] Arrangement of the sensor c onnections (schematic) on the LH (left figure) and RH ( rig ht figure) devices: A Product sensor B Signal outputs (optional) C Signal inputs (optional) D Rotary encoder (for automatic speed adaption) E Roll diameter sensor F Label sensor G (ALS 20x) Alterna[...]

13 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB 2.1.4 Mode of operation In labelling mode, the strip is first pulled from the label roll around the dancer arm [8A], which consistently maintains even tension in the label strip. The feed roller [8D] behind the dispensing edge [8C] draws the strip across the dispensing pla te. The label is unfixed from the [...]

14 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB 2.1.5 Technical specifications Characteristics 1) The maximum usable dispensing s peed depe nds on the label geome try. For details see separate performance matrix. 2) At a dispensing speed range of 5 m/min to the max. speed Labels 3) Depending on the dispensing ed ge width. Label sensor Power supply 4) For[...]

15 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB Electronics Interfaces Internal Interfaces 6) Not yet available Status messages, test functions, product profiles Processor: 32 Bit CPU MIPS Core RAM: 16 MB ROM: 4 MB Control panel: graphical d isplay with 128 x 32 pixels, 2/4 lines, 5 buttons Sensor interfaces for external s ensors Label sensor: Alternativ[...]

16 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB Dimensions 6) Measurements without the dispen si ng edge bracket and di spensing edge Environmental conditions Integration Certificates – CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA – The regulation DIN EN 550 22 demands for class A devices the following text to be printed in the manual: „WARNING: This i[...]

17 C ONTENTS 2.1 O VERVIEW ALS 20x 256 GB 2.1.6 Design models The ALS 20X and ALS 256 label dispensers are availa- ble in two designs fo r differi ng conveyor belt direction s. Right-handed version – The products are transpo rted from left to right [9]. – The dispensing edge is located on the right side. – Abbreviation: RH Left-handed version[...]

18 C ONTENTS 2.2 O PTIONS ALS 20x 256 GB External control panel – An external control panel can be conne cte d in addition to the integrated control panel. – An external control panel is useful if the standard control panel is difficult to access due to the position in which the unit is installed. Fixed dispensing edge – The dispensing ed ge [...]

19 C ONTENTS 2.2 O PTIONS ALS 20x 256 GB Pneumatic dispensing edge – The dispensing edge is pivoted in the dispensin g head. Compressed air presses the dispensing edg e onto the surface of the pr oduct. – Allows compensation for height differ ences between the products or on the product surface. V-shape dispensing edge – An alternative for ap[...]

20 C ONTENTS 2.2 O PTIONS ALS 20x 256 GB Outer Diameter control sensor The outer diameter control sensor (OD sensor) triggers a warning, if the label roll outer dia meter falls bel ow a certain, ad justable value. Printer – If necessary, you can mount a hot stamp printe r (not available from Avery Dennison) onto the holder brackets of the dispens[...]

21 C ONTENTS 2.3 O PERATING MODES ALS 20x 256 GB 2.3.1 Dispensing mode This is the operating mod e of the unit when switched on. You can carry out the f unctions listed below. If text such as ‘Prof 5 xxxxx xxx’ is displayed instead of ‘ONLI NE’: – The ‘xxxxx xxx ’ pr o du c t pr of ile (m em o ry location 5) is activated. – For more[...]

22 C ONTENTS 2.3 O PERATING MODES ALS 20x 256 GB Online settings The machine is in dispensing mode. To switch to the online settings mode: £ Press the button. – The display shows the dispensing speed [21A] and the start offset [21C]. – The button assignments are as shown on the buttons . – You can increase (‘+’ button) or lower (‘–?[...]

23 C ONTENTS 2.3 O PERATING MODES ALS 20x 256 GB 2.3.2 Configuration mode The machine is in dispensing mode. Switching to configuration mode: £ Press the button twice. – Display: £ Press the button. – Display: – LABEL SETUP is the name of the first menu that is currently active. – In configuration mode, the button assignmen ts are as show[...]

24 C ONTENTS 2.3 O PERATING MODES ALS 20x 256 GB Functions Every submenu contains func tions for setting the unit controls. Figure [23] shows the button functions for changing settings using the MACINE SETUP > Language function as an example. [23] Button functions for setting the MACHINE SETUP > Language function. A Button to ‘Accept change[...]

25 C ONTENTS 2.4 F UNCTION DESCRIPTIONS ALS 20x 256 GB 2.4.1 Function overview 1) Appears only when LABEL SETUP > Stop count. mode = ‘Enabled’ [24] Function menu ALS 20X and ALS 25 6 – Part 1. LABEL SETUP MACHINE SETUP INTERFACE PARA PLC INTERFACE APPLICATOR PARA Load prod. profil Store prod.prof. > EASYPLUGINTERPR End dispense mod Appl[...]

26 C ONTENTS 2.4 F UNCTION DESCRIPTIONS ALS 20x 256 GB 1) Only with integrated applicator interf ace. [25] Function overview in the ALS 20x menu – Part 2. SERVICE/DIAGNOS. SERVIC E DATA (continued) Sensor Test > MODULE FW VERS. > MEMORY DATA Compactflashtest System version Ram memory size Test functions Flash mem size > OPERATIONAL DATA [...]

27 C ONTENTS 2.4 F UNCTION DESCRIPTIONS ALS 20x 256 GB 2.4.2 Notes on function descript ions These operating instructio ns only describe those functions that are necessa ry for operating an ALS 20x that has b een configured and set up. Th ese functions are highlighted in grey in the function overview. Only qualified service technicians may change t[...]

28 C ONTENTS 2.4 F UNCTION DESCRIPTIONS ALS 20x 256 GB 2.4.5 SERVICE DATA menu If the displayed text is longer than the line length of the display: £ Press the button to move the text to the left. £ Press the button to move the text to the right. > MODULE FW VERS. submenu System version fu nct i on : – Shows the firmware version of the label[...]

29 C ONTENTS 3.1 E LECTRICAL CONNECTIONS ALS 20x 256 GB 3.1.1 Power supply connection WARNING! This machine o perates using mains voltage! Touching liv e el ec tric a l pa rts may exp os e you to hazardous electrical curre nts and may lead to burns. £ Make sure that th e device is swit ched of f before you c onnect the po wer cable. £ (ALS 20X)On[...]

30 C ONTENTS 3.1 E LECTRICAL CONNECTIONS ALS 20x 256 GB Checking the power supply setting ALS 256: A power supply s etting is not re- quired. The ALS 20X Label Dispenser is suitable for operation with a powe r supply of 230 V (AC) or 110 V (AC). If you are unsure of wha t mains voltage your local electricity supplier provides, refer to a qualified [...]

31 C ONTENTS 3.1 E LECTRICAL CONNECTIONS ALS 20x 256 GB 3.1.2 Connecting sensors £ Check whether the requir ed sensors are conn ected before turning on the unit [30]. The minimum require d sensors: – Label sensor (installation location: dispensing edge) – Product sensor (installation location: conveyor belt) Additional optio nal senso rs : –[...]

32 C ONTENTS 3.2 I NSERTING LABEL MATERIAL ALS 20x 256 GB 3.2.1 Prerequisites – The label dispenser is turned off at the main switch [31A] (switch set to ‘O’). £ Check that the safety in stallations are working properly. £ Inspect the machinery for any visible damage. Report any defects immediately. £ Remove any unnecessary materials and o[...]

33 C ONTENTS 3.2 I NSERTING LABEL MATERIAL ALS 20x 256 GB 3.2.2 Inserting a label roll WARNING! Risk of injury due to moving and rapidly rotating parts! £ Before inserting the la bel roll, ensure t hat the device is turned off at th e main switch. £ Do not under any circumstan ces turn the device on before the label strip is threaded i n comple t[...]

34 C ONTENTS 3.2 I NSERTING LABEL MATERIAL ALS 20x 256 GB 3.2.3 Threading the label ro ll Threading guide [34] Threading guide for label ro lls with labels facing outwards. A Right-handed version B Left-handed version [35] Threading guide for label ro lls with labels facing inwards. A Right-handed version B Left-handed version B A B A[...]

35 C ONTENTS 3.2 I NSERTING LABEL MATERIAL ALS 20x 256 GB Threading the label roll at the dispensing edge £ Unroll around 1 m of label strip and remove the labels from it. £ Pass the backing paper around the first deflection roller [36A] and thro ugh the slot in the sensor [36B]. £ Feed the backing paper under the pressure roller [36C] to the di[...]

36 C ONTENTS 3.2 I NSERTING LABEL MATERIAL ALS 20x 256 GB Threading the label ro ll onto the drive roller £ Open the pr essure roller. To do so, rotate the lever [37D] in a clockwise directio n. £ Feed the backing pa per around th e deflection roller [37B], drive roller [37C] and the dancer arm [37A]. £ Close the pressure roller. To do so, rotat[...]

37 C ONTENTS 3.3 M ECHANICAL SETTINGS ALS 20x 256 GB 3.3.1 Adjusting the unwinder’s core diameter Tool: – 3 mm hexagon (Allen) screwdriver The unwinder can be adjusted with core adapter s [40B] to fit the inner diameter of the label roll. The ad apters must be fitted and dismantled in different ways depending on this diameter: – 38.1 mm (1”[...]

38 C ONTENTS 3.3 M ECHANICAL SETTINGS ALS 20x 256 GB 3.3.3 Positioning the label sensor £ Release the thumb screw. £ Position the se nsor along the axle in such a way as to allow it to register the spaces between the labe ls. The LED [43A] lights up when the sensor is positioned over a label. [43] Label sensor from Wenglor, model OPT242-P800 B A[...]

39 C ONTENTS 4.1 S TART - UP AND SHUTDOWN ALS 20x 256 GB 4.1.1 Turning on the unit £ Set the main switch [44A] of the unit to ‘I’ (On). – The following messages are displa yed during the start proce ss: (machine type a nd firmware vers ion) (the machine’s RAM, as well as the CF card’s memory, if a card is inserte d) – Once switched on,[...]

40 C ONTENTS 4.1 S TART - UP AND SHUTDOWN ALS 20x 256 GB 4.1.3 Stopping the dispe ns ing process – The machine is in dispensing mod e: £ Press the button. – Display: – The dispenser stops. ONLINE Stopped: xxx[...]

41 C ONTENTS 4.2 C ONFIGURATION AND MONITORING ALS 20x 256 GB 4.2.1 Function menu settings Label pitch £ Switch to configuration mode Calibrating the label pitch automatically: £ Hold down the button for a while (longer than two seconds). Or: Enter the label pitch manually: £ Measure the label pitch [45C]. £ Call the LABEL SETUP > Label pitc[...]

42 C ONTENTS 4.2 C ONFIGURATION AND MONITORING ALS 20x 256 GB Dispensing speed You can set the dispensin g speed to a fixed value or you can configure it to automatical ly adjust to the speed of the conveyor belt (speed adaption). The second option requires you to connect a rotary encoder that measures and relays the conveyo r speed to the dispense[...]

43 C ONTENTS 4.2 C ONFIGURATION AND MONITORING ALS 20x 256 GB Label position on the product Prerequisite s: – The label length must be specified. – The label stop position must be set. Configuration in dispensin g mode: £ Use the two right buttons to set the st art offset (see “Online settings” on page 22). Or use the function menu setting[...]

44 C ONTENTS 4.2 C ONFIGURATION AND MONITORING ALS 20x 256 GB 4.2.2 Monitoring functions While in dispensing mode, an electr on ic controller monitors the following functions: Missing labels A label missing from the label roll does not nor mally affect the dispe nsing operation, b ecause the label fe ed continues until a label’s edge passes un de[...]

45 C ONTENTS 4.3 U SING PRODUCT PROFILES ALS 20x 256 GB 4.3.1 What are product profiles? Product profiles are memory locations th at can store all the settings for the machin e con tr ols . For re cu rrin g production jobs, they allow you to quickly set the machine to the respective product. – Number of m emory location s: 16 – The memory locat[...]

46 C ONTENTS 4.3 U SING PRODUCT PROFILES ALS 20x 256 GB button. – The profil e is saved. – Display: – The product profile has no w been saved. 4.3.4 Deleting a product profile £ Call the MACHINE SETUP > Del. prod.profil function. – The memory location that was active last is displayed. £ Press the or the button until you r etrieve the [...]

47 C ONTENTS 5.1 M AINTENANCE AND CLEANING ALS 20x 256 GB 5.1.1 Replacing fuses This section counts only for ALS 20X. The fu- ses at the ALS 256 cannot be replaced. WARNING! The machine operates using mains voltag e! Touching liv e el ec tric a l pa rts may exp os e you to hazardous electrical curre nts and may lead to burns. £ Make sure t hat the[...]

48 C ONTENTS 5.1 M AINTENANCE AND CLEANING ALS 20x 256 GB 5.1.2 Cleaning agents Cleaning agents for rubber ro ller s: – Roller cleaner, or de r number 98925. If other cleaning ag en ts ar e used , th er e is a chance the rubber may corro de. Cleaning agents for metal deflection rollers: – Cleaning solv ent, alcohol-b ased solvent, isopropyl alc[...]

49 C ONTENTS 5.1 M AINTENANCE AND CLEANING ALS 20x 256 GB 5.1.3 Regular maintenance The label dispenser is designed to be maintenance-free. However, you should se rvice the unit regularly in order to ensure r eliable long-term operating results. Depending on operating cond itions, you should perform the following at least once a week: £ Carry out [...]

50 C ONTENTS 6.1 E RROR MESSAGES ALS 20x 256 GB 6.1.1 Reporting errors When an error occu rs, the ma ch ine stops immed i ately and displays an error message on th e control panel. Error messag es are displayed as follows: [52] An example of an error message: 5144 = status number; this number makes it easier to identify the message. ‘Rewinder ini[...]

51 C ONTENTS 6.1 E RROR MESSAGES ALS 20x 256 GB 5026 MotorProtect CPU – ( ALS 256) Dust filter liner exhausted. This leads to overheating the ma- chine. – (ALS 20X) Voltage selec tion switc h set faulty. – There are some more po ssible caus- es, which require a qualified service technician to cure. £ Renew the dust filter liner. £ Check set[...]

52 C ONTENTS 6.1 E RROR MESSAGES ALS 20x 256 GB 5147 Tandemsync h. Init This message can only ap pe a r during tandem oper ation. – Communication between the maste r and slave machines is not function- ing. £ Check tandem interface ca ble. – Is it a) in place and b) correctly con- nected? £ Check the settings on both ma- chines. – Siehe “[...]

53 C ONTENTS 7.1 EU D ECLARATION OF C ONFORMITY ALS 20x 256 GB We, Avery Dennison Deutschl and GmbH Ohmstrass e 3 85386 Eching , Germany herewith asse rt th at we hav e de sig ne d an d built the de vice described in the following to conform with the basic safety and health requirements of the re levant EU directives. Eching, 21 March 2006 Name of [...]

Avery Dennison Deutschland GmbH Ohmstrasse 3 85386 Eching Germany Phone: +49-8165-925-0 http://www.machines.averydennison.com[...]