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ALS 206
User Manual
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Avery ALS 206, ALS 204, ALS 256 User Manual

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Page 1
OPERATING INSTRUCTIONS
Label Dispenser
ALS
204/206 256
Edition 04/2007
Page 2
Page 3
CONTENTS
20x 256
GB
1 Please note
1.1 General notes
1.1.1 Validity and binding effect of this manual . . . . 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Technical status . . . . . . . . . . . . . . . . . . . . . . . . .1
Copyright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1.2 Illustrations and descriptions. . . . . . . . . . . . . . 2
Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . 2
Dangers and risk notes . . . . . . . . . . . . . . . . . . . .2
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Button symbols . . . . . . . . . . . . . . . . . . . . . . . . . .2
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Supplementary information . . . . . . . . . . . . . . . . .2
1.2 Safety instructions
1.2.1 Information and qualifications. . . . . . . . . . . . . 3
Follow the instructions. . . . . . . . . . . . . . . . . . . . .3
Keep the product information at hand. . . . . . . . . 3
Ensure the required qualifications are met . . . . .3
1.2.2 Operational safety of the unit . . . . . . . . . . . . . 4
Proper usage. . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Protection against injuries by electrical current. .4 Protection against injuries by mechanical action.5
Protection against injuries by chemicals . . . . . . .5
1.2.3 Before beginning production. . . . . . . . . . . . . . 6
Due diligence of the operating company and the
service technician . . . . . . . . . . . . . . . . . . . . . . . .6
Due diligence of the user. . . . . . . . . . . . . . . . . . .6
1.2.4 Safety notes on the unit . . . . . . . . . . . . . . . . . 7
2 Product description
2.1 Overview
2.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Control panel. . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating LED. . . . . . . . . . . . . . . . . . . . . . . . . .10
Error LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
LCD display. . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1.3 Connection arrangement . . . . . . . . . . . . . . . 11
Connections on the back of the device . . . . . . .11
Sensor connections. . . . . . . . . . . . . . . . . . . . . .12
2.1.4 Mode of operation. . . . . . . . . . . . . . . . . . . . . 13
2.1.5 Technical specifications . . . . . . . . . . . . . . . . 14
Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . .14
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Label sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Internal Interfaces . . . . . . . . . . . . . . . . . . . . . . .15
Status messages, test functions,
product profiles . . . . . . . . . . . . . . . . . . . . . . . . .15
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Environmental conditions . . . . . . . . . . . . . . . . .16
Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.1.6 Design models . . . . . . . . . . . . . . . . . . . . . . . 17
Right-handed version . . . . . . . . . . . . . . . . . . . .17
Left-handed version. . . . . . . . . . . . . . . . . . . . . .17
2.2 Options
External control panel . . . . . . . . . . . . . . . . . . . .18
Fixed dispensing edge. . . . . . . . . . . . . . . . . . . .18
Swivelling dispensing edge . . . . . . . . . . . . . . . .18
Spring-loaded dispensing edge. . . . . . . . . . . . .18
Pneumatic dispensing edge . . . . . . . . . . . . . . .19
V-shape dispensing edge . . . . . . . . . . . . . . . . .19
Adjustable dispensing edge holder . . . . . . . . . .19
Outer Diameter control sensor . . . . . . . . . . . . .20
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Applicator interface . . . . . . . . . . . . . . . . . . . . . .20
Dust/Splash guard. . . . . . . . . . . . . . . . . . . . . . .20
2.3 Operating modes
2.3.1 Dispensing mode . . . . . . . . . . . . . . . . . . . . . 21
Stopping/Continuing the dispensing mode . . . .21
Changing the counter reading . . . . . . . . . . . . . .21
Starting the unit in configuration mode . . . . . . .21
Counting labels backwards . . . . . . . . . . . . . . . .21
Online settings. . . . . . . . . . . . . . . . . . . . . . . . . .22
2.3.2 Configuration mode . . . . . . . . . . . . . . . . . . . 23
Function of the double-arrow button . . . . . . . . .23
Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.4 Function descriptions
2.4.1 Function overview . . . . . . . . . . . . . . . . . . . . 25
2.4.2 Notes on function descriptions. . . . . . . . . . . 27
2.4.3 LABEL SETUP menu. . . . . . . . . . . . . . . . . . 27
2.4.4 MACHINE SETUP menu . . . . . . . . . . . . . . . 27
2.4.5 SERVICE DATA menu. . . . . . . . . . . . . . . . . 28
> MODULE FW VERS. submenu . . . . . . . . . . .28
> OPERATIONAL DATA submenu . . . . . . . . . .28
>POWER SUPPLY DATA submenu . . . . . . . . .28
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> 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 connections
3.1.1 Power supply connection . . . . . . . . . . . . . . . 29
Checking the power supply setting . . . . . . . . . .30
Connecting the power cable.. . . . . . . . . . . . . . .30
3.1.2 Connecting sensors . . . . . . . . . . . . . . . . . . . 31
3.2 Inserting label material
3.2.1 Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2.2 Inserting a label roll. . . . . . . . . . . . . . . . . . . . 33
Removing spent backing paper. . . . . . . . . . . . .33
Removing glue residue . . . . . . . . . . . . . . . . . . .33
Inserting a new label roll . . . . . . . . . . . . . . . . . .33
3.2.3 Threading the label roll . . . . . . . . . . . . . . . . . 34
Threading guide . . . . . . . . . . . . . . . . . . . . . . . .34
Threading the label roll at the dispensing edge.35 Threading the label roll onto the drive roller . . . 36
Fastening the label roll to the rewinder . . . . . . .36
3.3 Mechanical settings
3.3.1 Adjusting the unwinder’s core diameter . . . . 37
3.3.2 Positioning the pressure roller . . . . . . . . . . . 37
3.3.3 Positioning the label sensor . . . . . . . . . . . . . 38
Material end. . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Material tear. . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.3 Using product profiles
4.3.1 What are product profiles?. . . . . . . . . . . . . . 45
4.3.2 Loading a product profile . . . . . . . . . . . . . . . 45
4.3.3 Storing a product profile. . . . . . . . . . . . . . . . 45
Selecting the memory location . . . . . . . . . . . . .45
Entering profile names. . . . . . . . . . . . . . . . . . . .45
4.3.4 Deleting a product profile. . . . . . . . . . . . . . . 46
5 After operation
5.1 Maintenance and cleaning
5.1.1 Replacing fuses . . . . . . . . . . . . . . . . . . . . . . 47
5.1.2 Cleaning agents. . . . . . . . . . . . . . . . . . . . . . 48
5.1.3 Regular maintenance. . . . . . . . . . . . . . . . . . 49
Removing paper debris . . . . . . . . . . . . . . . . . . .49
Renewal of the dust filter liner (ALS256) . . . . .49
6 Operational failures
6.1 Error messages
6.1.1 Reporting errors. . . . . . . . . . . . . . . . . . . . . . 50
6.1.2 List of error messages . . . . . . . . . . . . . . . . . 50
7 Appendix
7.1 EU Declaration of Conformity
4 Operation
4.1 Start-up and shutdown
4.1.1 Turning on the unit . . . . . . . . . . . . . . . . . . . . 39
4.1.2 Starting label dispensing. . . . . . . . . . . . . . . . 39
Dispensing with a product sensor . . . . . . . . . . .39
Dispensing without a product sensor . . . . . . . .39
4.1.3 Stopping the dispensing process . . . . . . . . . 40
4.2 Configuration and monitoring
4.2.1 Function menu settings. . . . . . . . . . . . . . . . . 41
Label pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Label stop position . . . . . . . . . . . . . . . . . . . . . .41
Dispensing speed . . . . . . . . . . . . . . . . . . . . . . .42
Label position on the product . . . . . . . . . . . . . .43
4.2.2 Monitoring functions . . . . . . . . . . . . . . . . . . . 44
Missing labels . . . . . . . . . . . . . . . . . . . . . . . . . .44
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1.1 GENERAL NOTES

1 PLE ASE NOTE

1.1 GENERAL NOTES

1.1.1 Validity and binding effect of this manual Contents

The present manual refers exclusively to the ALS 204, ALS 206 and ALS256 label dispensers. It is written for the purpose of ensuring professional usage and calibration of the unit.
Prerequisites for the use and adjustment are the professional installation and configuration of the unit.
For any technical questions you may have that are not described in this manual, see:
£ The service manual of the label dispenser
or
£ Request a technician from one of our sales partners.
– Our sales representatives are available to assist
you, particularly with configuring the unit as well as in the case of malfunctions.
Technical status
Copyright
Avery Dennison holds all rights to this manual and its appendices. Reproduction, reprinting or any other types of duplication, even of portions of this manual, may only be carried out with express written consent. Third persons, in particular competitors, should not be given access to the information in this manual.
Printed in Germany
Manufacturer
Avery Dennison Deutschland GmbH Ohmstrasse 3 85386 Eching, Germany Phone: +49-8165-925-0 Fax: +49-8165-3143 http://www.machines.averydennison.com
256
GB
Technical status: 04/2007 Software version: 1.02
Avery Dennison reserves the right: – To make modifications to construction parts,
components and software, as well as to employ comparable components in place of the parts
specified, in keeping with technical advances. – To modify information in this document. No commitment will be made to expand these modifications to include any units delivered earlier.
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CONTENTS
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1.1 GENERAL NOTES

1.1.2 Illustrations and descriptions Signs and symbols

Various information types are indicated in diff er en t ways within the document in order to simplify readability and comprehension.
Sentences starting with an arrow are instructions and guidelines.
£ Perform the instructions one after another in the
specified order. The following information begins with a dash:
–Lists – Mode descriptions – Descriptions of prior steps – Prerequisites for following actio ns
Dangers and risk notes
Important directions that you must absolutely observe are particularly emphasized:
WARNING!
A warning refers to risks that can lead to serious injury or death! The warning contains safety measures to protect the relevant persons.
£ Always follow the instructions.
CAUTION!
A caution indicates risks that can lead to property damage or injuries to persons (minor injuries). The caution note contains instructions for preventing da ma ge s .
£ Always follow the instructions.
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GB
Figures
Texts are accompanied by figures where necessary. Figures are indicated using figure numbers in [square brackets]. A capital letter after a figure number, for example [12A], refers to a specific section of the figure. Generally, the label dispenser shown is an ALS 104 right-handed version. The left-handed version is only shown where it is necessary to differentiate between the two.
Button symbols
– The buttons of the control panel are depicted as
symbols.
– The symbols are depicted with a ‘+’ (PLUS SIGN)
between them if more than one button is to be pressed. +
Parameters
Parameters are displayed in grey in the text with the following structure, MENU NAME > Function name.
Supplementary information
The expert symbol indicates actions that are only to be performed by qualified and specially trained personnel.
The information symbol indicates notes and recommendations, as well as additional information.
Equipment: – Equipment, for example lubricants or
cleaning agents
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1.2 SAFETY INSTRUCTIONS

1.2 SAFETY INSTRUCTIONS

1.2.1 Information and qualifications Follow the instructions

WARNING!
Safe and efficient operation of the label dispenser can only be guaranteed if you observe all necessary information.
Product liability and warranty claims can only be asserted if the unit was operated in accordance with the directions in the manual.
£ Before operating the unit, read the
operating instructions and all other notes carefully.
£ Observe the additional safety and
warning notes on the label dispenser.
£ Only permit competent people to operate
and configure the label dispenser.
Keep the product information at hand
With respect to this manual:
£ It should be kept at the location where the
unit is installed and be available to the operator.
£ It should always be legible. £ If the unit is sold, the manual should be made
available to the new owner.
£ The safety and warning notes affixed to the
unit itself must be kept clean and legible. Missing or damaged signs must be replaced.
256
GB
Ensure the required qualifications are met
£ Ensure that only trained and authorized personnel
operate, configure and service the un it.
£ Only allow qualified and well-trained expert
personnel or service technicians to perform configurations.
£ The responsibilities with regard to operation,
configuration and maintenance shou ld be cl ea rly defined and consistently maintained.
£ In addition, personnel should also be instructed on
a regular basis in matters of occupational safety and environmental protection.
Qualification for operation
The instruction of personnel using the unit must ensure that: – The operating personnel can use the unit on their
own and safely.
– The operating personnel can remedy small
operational disruptions on their own.
£ At least two people must be instructed in the unit’s
usage.
£ Enough label material must be provided for testing
and instructional purposes.
Qualifications for configuring
The configuration of the controls requires qualified expertise: – Personnel configuring the unit must be
acquainted with the functionality of the label dispenser.
– Personnel configuring the unit must be
acquainted with the modes of operation within the facility in which the label dispenser is integrated.
– The personnel co nfiguring the unit must be
able to use the additional menus properly and appropriately for specific project requirements.
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1.2 SAFETY INSTRUCTIONS

1.2.2 Operational safety of the unit Proper usage

The ALS20x Label Dispenser is a fully automatic unit for attaching self-adhesive labels to products or packaging. The company operating the unit must install it with suitable equipment to protect operating personnel from danger; for example, the danger of the hands or fingers being crushed by reaching in between the product and the dispensing edge.
WARNING!
Improper usage of the unit can cause accidents, property damage and production downtime!
£ Only use the unit in accordance with the
instructions specified in this manual.
£ Do not ope rate the unit without the
required safeguards.
£ Only configure the unit in accordance
with this manual and with the required care.
£ Only use original accessories. £ Do not make any modifications or
alterations to the unit.
£ Repairs to the device may only be
performed by authorised specialists who are aware of the risks involved.
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GB
WARNING
The unit is not protected against splashing water in its standard model.
£ Keep the unit dry. £ If liquids have penetrated the unit, switch
it off and disconnect or unplug the power cable immediately. Inform a service technician.
WARNING
The device is only completely disconnected from the mains if the power cable is
unplugged.
£ Make sure the power supply socket is
accessible.
£ In case of emergency, switch off the
device and disconnect the power cable.
CAUTION
A too high or low supply voltage can damage the unit.
£ Only operate the device using the system
voltage indicated on the nameplate.
£ Ensure that the mains voltage set on the
unit is the same voltage as that provided by the electricity supplier.
Protection against injuries by electrical current
WARNING!
The machine operates using mains voltage! Touching live electrical parts may exp os e you to hazardous electrical currents and may lead to burns.
£ Only operate the unit once the housing
has been reassembled properly.
£ Only connect the unit to a properly fitted
power socket that is grounded.
£ Before cleaning, switch off the unit and
remove the power cable from the socket.
£ Only link the unit to devices that fulfil the
SELV (safety extra-low voltage) circuit requirements specified in EN60950.
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1.2 SAFETY INSTRUCTIONS
Protection against injuries by mechanical action
WARNING!
Risk of injury due to moving and rapidly rotating parts!
– Long hair, loose jewellery, long sleeves,
and so on are not permissible when using the unit.
£ Sufficient protective clothing must be
worn.
£ Keep moving parts free from
obstructions even when the unit is not switched on, if there is a chance the machine might be turned on.
£ Switch off the machine before making
any mechanical settings.
£ Do not wear ties, loose clothing,
jewellery, wrist watches or similar items on your person when near the operating unit.
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GB
WARNING!
There is a risk that you may get your fingers or hands crushed on the dispensing edge by products on the conveyor belt!
£ Never reach between the product and the
dispensing edge while the uni t is in operation or ready for operation.
£ Never reach behind the safety guard or
remove it while the unit is in operation.
Protection against injuries by chemicals
CAUTION!
Operating materials such as cleaning agents or the solvents in glues can be damaging to health.
£ Always follow the instructions, use and
safety regulations specified by the manufacturer!
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CONTENTS
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1.2 SAFETY INSTRUCTIONS

1.2.3 Before beginning production Due diligence of the operating company

and the service technician
£ Ensure that the following prerequisites are fulfilled in
accordance with the service instructions: – The machine is installed properly and configured in
accordance with the guidelines. – All required safety mechanisms ha ve been installed. – The unit has perform ed at least one successfu l test
run. – The unit is connected to the power supply.
£ The users have the required personal protective
equipment, for example, a hairnet. Ensure that the
protective equipment is utilised correctly.
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GB
Due diligence of the user
£ Check that the safety installations are working
properly.
£ Inspect the machinery for any visible damage.
Report any ascertained defects immediately.
£ Use the required personal protective equipment
correctly, for example, wear a hairnet.
£ Remove any unnecessary materials and objects
from the operating area of the unit.
£ Ensure that on ly au th or ise d pe rs on s ar e with in th e
operating range of the machine.
£ Ensure that starting up the machine will not injure
anyone.
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CONTENTS
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1.2 SAFETY INSTRUCTIONS

1.2.4 Safety notes on the unit

CAUTION!
Warning notes on the unit represent important information for the personnel using it.
£ Do not remove warning notes. £ Replace any missing or illegible
warnings.
The ‘Pinch Point’ warning [1] note warns you of the danger posed by the machine’s ro tating parts; they can trap items and draw them in.
!
WARNING
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GB
Pinch point.
Keep hands clear of rollers.
A5346
[1] Left: ‘Pinch Point’ warning. Right: Position of the warning note on the ALS 20x. Item number of the label: A5346.
The blue label ‘Read manual’ [2] demands that users read the unit instructions.
Handbuch lesen! Read the manual! Lisez le manuel! Lea el manual! Legga il manuale!
[2] Left: ‘Read manual’ notice. Right: Position of the notice on the ALS20x. Item number of the label: A5331.
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2.1 OVERVIEW

2 PRODUCT DESCRIPTION

2.1 OVERVIEW

2.1.1 Components

A
256
GB
CD
B
O
E
F
N
M
L
G
K
H
I
[3] ALS204 Label Dispenser (right-handed version)
J
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CONTENTS
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2.1 OVERVIEW
A Control panel – For sending commands to the device and for
displaying operating states and error messages. – An optional external control panel can also be
connected to the device. B Dancer arm
– Keeps the label material stretched tight evenly. – Arrests the rotation of the material roll if tension
diminishes. C Dispenser
– Dispenser mandrel grasps the label roll. D Core diameter adapter
– For adjusting the diameter of the dispenser mandrel
to match the core diameter of the label roll. E Adjusting knob
– Turning this in a clockwise direction secures the
label roll on the dispenser. F Deflection rollers G Dispensing edge bracket H Label sensor
– Stops the label feed after a label has been
dispensed.
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J Dispensing edge – Standard: (non-adjustable) L-shaped dispensing
edge
– The following options are available: V-shaped
dispensing edge, adjustable L-shaped dispensing edge, spring-loaded L-shaped dispensing edge, pneumatic L-shaped dispensing edge
K Drive roller – Drives the label material forwards.
L Pressure mechanism – Presses the pressure roller against the drive roller. – Prevents the backing paper from slipping through. – Releases automatically once the backing paper has
been drawn around the drive roller.
M Dancer arm – Controls the rewind speed.
N Rewinder – Rolls up the used backing paper.
O Release button – Pressing this button reduces the diameter of the
rewinder core.
– Allows the easy removal of the rewound backing
paper.
I Pressure roller – Prints the label once it is stuck to the product.
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2.1 OVERVIEW

2.1.2 Control panel Operating LED

Lights up green when the device is switched on.
Error LED
Lights up red when an error occurs.
LCD display
– Displays functions, configured values, operating
states and error messages. – What is displayed at any one time depends on the
operating status of the device; these screens are
explained in the section “Operating modes” on
page 21.
A B
C
D
[4] The ALS20x control panel (in dispensing mode)
A Operating LED B Error LED C LCD display D Buttons
ON
STATUS
Labels
–
Online
+
–
292
+
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GB
Buttons
The functions of the buttons depend on the operating status of the device; these functions ar e exp la ine d in the section “Operating modes” on page 21.
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CONTENTS
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2.1 OVERVIEW

2.1.3 Connection arrangement

Connections on the back of the device
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B
C
D
E
F
A
[5] Connections on the back of the device (ALS20x):
A Power supply connection B Network connection (Ethernet 10/100) C Serial interface (RS232) D Connection for external control panel (RS485)
For information on connecting the unit, see sec­tion “Power supply connection” on page 29.
G
H
E Plug-in card slot (CompactFlash cards) F USB device interface G PLC signal interface H Optional: Applicator interface
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2.1 OVERVIEW
Sensor connections
C B
A
256
GB
[6] Sensor connections on the ALS20x (RH)
B C
A
PLC-IN
PLC-OUT
E D
START
F
OD
G
CAP
[7] Arrangement of the sensor connections (schematic) on the LH
(left figure) and RH (right 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 (ALS20x) Alternative label sensor H (ALS 256) Alternative label sensor
For information on connecting the sensors, see section “Connecting sensors” on page 31.
ROTARY
ENCODER
CAP for 256
LABEL
H H
PLC-OUT
PLC-IN
D E
START
F
LABEL
ROTARY
ENCODER
CAP for 256
OD
G
CAP
RHLH
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2.1 OVERVIEW

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 plate. The label is unfixed from the backing paper on the dispensing plate and is pressed onto the product by the pressure roller [8B].
The feed roller drives the label strip forwards the length of one label and stops until the next product arrives at the dispensing plate. The strip feed is started by the product sensor mounted on the conveyor belt. T he stop control provided by the label sensor on the dispensing edge ensures the feed is halted as soon as a gap is de­tected between two labels.
The spent backing paper runs from the dispensing edge around the drive roller [8D] to the rewinder [8E]. The dancer arm regulates the rewinding speed.
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A
E
D
The entire operation of the label dispenser is controlled and monitored electronically. If errors occur, the d evice controls output an appropriate notification for the oper­ator. If necessary, the labelling operating mode is halt­ed automatically. An electronic signal is output at the same time. The signal can be fed to an external control­ler and evaluated.
B
C
[8] The ALS20x Label Dispenser is ready for operation in its
idle mode.
A Dancer arm B Pressure roller C Dispensing edge D Drive roller E Rewinder
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CONTENTS
20x
2.1 OVERVIEW

2.1.5 Technical specifications

Characteristics
Dispensing speed 1):
ALS204 ALS206 ALS256
Labelling halt precision at the peeling edge:
Speed control: Fixed setting or automatic
1) The maximum usable dispensing speed depends on the label geometry. For details see separate performance matrix.
2) At a dispensing speed range of 5m/min to the max. speed
Labels
Label material: Converted self-adhesive
Internal rewinding yes Material width (including
backing paper)
ALS204 ALS206
ALS256 Label length: 5 to 600mm Label roll:
Winding direction
Dispenser (outer) Ø:
Rewinder (outer) Ø:
Core (inner) Ø:
3) Depending on the dispensing edge width.
3)
:
max. 40m/min max. 30m/min max. 50m/min
2)
±1 mm
speed adaption via the rotary encoder
label material with liner
up to 110mm up to 160mm up to 160mm
inner or outer up to 300mm up to 200mm
38.1/76.2 /101.6mm (1.5/3 /4")
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Label sensor
Distance to peel edge
L-shape dispensing edge: V-shape dispensing edge:
Transmission sensor: Wenglor OPT242-P800
Power supply
System voltage:
ALS20X
ALS256
Power consumption:
ALS20X ALS256
Fuses:
ALS20X ALS256
4) For more information on fuses, see section “Replacing fuses” on page 47.
5) Not accessible for user or service technician.
19mm 77mm
optical, NPN
110V (AC) at 60Hz pow­er frequency (permissible tolerance ±10%)
230V (AC) at 50Hz pow­er frequency (permissible tolerance ±10%)
100-240V (AC) at 50-60Hz power frequen­cy (permissible tolerance ±10%)
max. 460VA max. 560VA
F1, F2: T5AH 250V Fuses integrated in the power supply
4)
5)
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CONTENTS
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2.1 OVERVIEW
Electronics
Processor: 32Bit CPU MIPS Core RAM: 16MB ROM: 4MB Control panel: graphical display with
128x32 pixels, 2/4 lines, 5 buttons
Interfaces
Sensor interfaces for external sensors
Label sensor:
Alternative label
sensor:
Product sensor:
APSF-sensor (Rotary
encoder):
Stock sensor: Internal sensor interfac-
es:
Material unwinder
Pressure roller
Dancer arm
PLC interface
Outputs:
Inputs:
(plug in each case 4­pin M12)
Wenglor OPT242-P800 optical, NPN, 24V, con­trollable sensitivity
PNP/NPN, 24V
PNP/NPN, 24V single-phase/two-phase,
PNP/P-P, 24V, max. 20kHz
PNP, 24V
Light barrier not used bi-phase light barrier en-
coder Sub D15, optically insu-
lated, optionally via two 8-pin M12 (separate in­puts/outputs in each case)
4x PNP, 24V, a maxi­mum of 500mA/channel, total permissible output current: 1500mA
3x PNP/NPN, 24V
256
Data interfaces:
Serial:
Ethernet: USB:
CF card:
Control panel interface:
Internal Interfaces
RFID Connection for RFID
Applicator Interface Connection for Applicator
Connector for additional motor driver
6) Not yet available
Status messages, test functions, product profiles
Automatic halt, if ... the label roll is spent or
Test functions: Automatic diagnostics
Status indicators: Label counter
Storage locations for product profiles:
RS232C (Sub-D9), max. 115200 Baud
10/100 BaseT (RJ45) Device V1.1 (USB B),
‘Full speed’ operating mode, 12MBit/s
Slot for 1 CompactFlash card
RS485 (Mini DIN 6 con­nection) for remote con­trol
read/write unit (special equipement)
Interface (AI) board (spe­cial equipement)
not used
no gap was found. ...the max. admissible number of missing labels is reached.
check when switched on Output of system data via
data interface
Operating hours counter up to 16
6)
GB
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CONTENTS
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2.1 OVERVIEW
Dimensions
Width x height x depth:
ALS204
ALS206
ALS256 Weight:
ALS204
ALS206
6) Measurements without the dispensing edge bracket and dispensing edge
Environmental conditions
Operating temperature: 5 to 40°C Humidity: 30 to 85%, (non-con-
Noise (at a distance of 1m):
Protection class: IP 21
Integration
Mounting positions: side / bottom / rear
6)
492 x 488 x 353mm 492 x 488 x 403mm 492 x 488 x 403mm
36kg 38kg
densing) 72dB(A)
IP 65 special equipment for ALS20X
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Certificates
– CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA – The regulation DIN EN 55022 demands for class A
devices the following text to be printed in the manual:
„WARNING: This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.“
– The FCC regulation demands the following
information text for class A devices: „NOTE: This equipment has been tested and found
to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense“
Labelling positions: top / side / bottom Dispensing edges: V-shape
L-shape fixture 90° pivoting, for all L-shape types (4“ L-shape disp. edge: material width up to 100mm only)
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CONTENTS
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2.1 OVERVIEW

2.1.6 Design models

The ALS20X and ALS256 label dispensers are availa­ble in two designs for differing conveyor b elt directions.
Right-handed version
– The products are transported from left to right [9]. – The dispensing edge is located on the right side. – Abbreviation: RH
Left-handed version
– The products are transported from right to left [10]. – The dispensing edge is located on the left side. – Abbreviation: LH
B
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A
C
The label dispenser operation described in this manual is based on the right-handed version. The left-handed version is only taken into ac­count if the explanations or figures of the de­signs differ significantly.
[9] Right-handed version
A ALS20X B Product on the conveyor belt C Labelled product
[10] Left-handed version
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CONTENTS
20x

2.2 OPTIONS

2.2 OPTIONS

External control panel

– An external control panel can be connected in
addition to the integrated control panel.
– An external control panel is useful if the standard
control panel is difficult to access due to the position in which the unit is installed.

Fixed dispensing edge

– The dispensing edge has a fixed connection to the
brackets.
– To adjust the vertical position, lift/lower the entire
device.
– The slope angle can be adjusted by rotating the
brackets (see the service manual for further details).
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[11] External control panel

Swivelling dispensing edge

– The position of the dispensing edge can be adjusted
vertically.
– The device need not be moved to adjust the position
of the dispensing edge; the device’s mounting need not be dismantled.

Spring-loaded dispensing edge

– The dispensing edge is pivoted. A torsion spring in
the dispensing head presses the dispensing edge downwards and onto the surface of the product.
– Allows compensation for height differences
between the products or on the product surface.
[12] Standard dispensing edge
[13] Swivelling dispensing edge
[14] Spring-loaded dispensing edge
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2.2 OPTIONS

Pneumatic dispensing edge

– The dispensing edge is pivoted in the dispensing
head. Compressed air presses the dispensing edge onto the surface of the product.
– Allows compensation for height differences
between the products or on the product surface.
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V-shape dispensing edge

– An alternative for applications which do not leave
enough space for the standard dispensing edge hol­der, which juts out to the bottom side.
– Is attached directly to the machine

Adjustable dispensing edge holder

Enables a vertical fine adjustment of the dispensing edge towards the product without moving the machine.
[15] Pneumatic dispensing edge
[16] V-shape dispensing edge
[17] Adjustable dispensing edge holder (pictured red resp. dark
gray)
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CONTENTS
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2.2 OPTIONS

Outer Diameter control sensor

The outer diameter control sensor (OD sensor) triggers a warning, if the label roll outer diameter falls below a certain, adjustable value.

Printer

– If necessary, you can mount a hot stamp printer (not
available from Avery Dennison) onto the holder brackets of the dispensing edge.
– Example of use: Printing consecutive numbers onto
labels.

Applicator

If it is not possible to label directly from the dispensing edge, you can fit an applicator to the label dispenser. Various types of applicators are available that depend on the given requirements.
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[18] OD sensor (pictured red resp. dark gray)
Simple applicators can be controlled directly via the PLC signal interface [5G] that is available as standard.

Applicator interface

Additional board [5H]; allows almost all types of applicators to be controlled.

Dust/Splash guard

Available only for ALS20X. Additional sealing of the electrical connection s an d of
the housing fulfils the requirements of the IP65 protection class [19].
[19] Dust/splash guard of the electrical connections (pictured red
resp. dark gray)
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CONTENTS
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2.3 OPERATING MODES

2.3 OPERATING MODES

2.3.1 Dispensing mode

This is the operating mode of the unit when switched on. You can carry out the functions listed below.
If text such as ‘Prof 5 xxxxxxxx’ is displayed instead of ‘ONLINE’: – The ‘xxxxxxxx’ product profile (m em o ry
location 5) is activated.
– For more information, see the ‘Using product
profiles’ section.
Stopping/Continuing the dispensing mode
Stopping the dispensing mode:
£ Press the button.
– Display:
ONLINE
Stopped: xxx
256
ON
STATUS
Online
–
292
+
Labels
–
A
[20] Control panel in dispensing mode (292 labels dispensed)
A Explanation of buttons in dispensing mode
+
GB
Continuing the dispensing mode:
£ Press the button.
Changing the counter reading
£ Set the counter reading using the MACHINE SETUP >
Dispense counter function.
Starting the unit in configuration mode
To start the unit in configuration mode:
£ Set MACHINE SETUP > Turn-on mode to ‘Offline’.
Counting labels backwards
To count dispensed labels backwards from a starting value to zero:
£ Set LABEL SETUP > Stop count. mode to ‘Enabled’. £ Use the LABEL SETUP > Label stop quan. function to
define the starting value.
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2.3 OPERATING MODES
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 (‘–’ button)
both settings in the dispensing mode [21D].
Dispensing speed: – Setting range:
ALS204: [2.0…40.0] m/min
ALS206: [2.0…30.0] m/min – Display fix: The dispensing speed is constant. – Display var: The dispensing speed automatically
adjusts to the speed of the conveyor belt (‘speed
adaption’). Start offset:
– Setting range: [0.0…999.9] mm – The start offset indicates the distance between the
product sensor and the dispensing edge.
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ABC
ON
STATUS
–
Offset
0.0
+
D
Speed
12.2 fix
–
+
EFGH
[21] Control panel in the online settings mode
A Dispensing speed display (here: 12.2 m/min constant) B Dispense label button C Start offset display (here: 0 mm) D Explanation of buttons in online settings mode E Button to lower dispensing speed F Button to increase dispensing speed G Button to lower start offset H Button to increase start offset
Dispensing manually
– To manually trigger the dispensing of individual
labels:
£ Press the button.
– Dispensing speed: As specified in the setting (see
above). To switch back to dispensing mode:
£ Press the buttons + .
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2.3 OPERATING MODES

2.3.2 Configuration mode

The machine is in dispensing mode. Switching to configuration mode:
£ Press the button twice.
– Display:
OFFLINE
£ Press the button.
– Display:
LABEL SETUP
– LABEL SETUP is the name of the first menu that is
currently active. – In configuration mode, the button assignments are
as shown below the buttons.
ON
STATUS
OFFLINE
–
+
LABEL SETUP
MACHINE SETUP
A
–
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+
B
Function of the double-arrow button
To dispense individual labels:
£ Press the button briefly (less than two
seconds). – Dispensing speed: As specified in the configuration;
‘Speed Adaption’ is not active. To automatically calibrate the label length:
£ Hold down the button for a while (longer than
two seconds).
Menus
In configuration mode, you have access to several menus providing a fixed sequence of functions that can be carried out.
You can set the unit so that some of the menu s are not shown.
Figure [22] shows the button functions for switching between the individual menus and for leaving them.
INTERFACE. PARA
I/O BOARD
APPLICATOR PARA
SERVICE/DIAGNOS.
SERVICE DATA
[22] Menu selection and button functions in configuration mode.
A Button for triggering a dispensing procedure and for
starting the measurement of lengths.
B Explanation of buttons in configuration mode C Menus
C
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2.3 OPERATING MODES
Functions
Every submenu contains functions for setting the unit controls.
Figure [23] shows the button functions for changing settings using the MACINE SETUP > Language function as an example.
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MACHINE SETUP
MACHINE SETUP Store Prod.Prof.
23x
MACHINE SETUP Language
Language English
AB
Language German
[23] Button functions for setting the MACHINE SETUP >
Language function.
A Button to ‘Accept changes’ B Button to ‘Cancel changes’
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2.4 FUNCTION DESCRIPTIONS

2.4 FUNCTION DESCRIPTIONS

2.4.1 Function overview

LABEL SETUP MACHINE SETUP INTERFACE PARA PLC INTERFACE APPLICATOR PARA
Load prod. profil Store prod.prof. > EASYPLUGINTERPR End dispense mod Applicator type Dispense speed Del. prod.profil Interface Disp. end delay Apply mode Slew speed Sensor Adjust Spooler mode Disp. end time Blow on time Label pitch Dispense counter Printer ID no. Restart delay Lab. stop offset Factory settings Spooler size Position timeout Start offset Parameter to CF Interface delay Start error stop Product length Auto Sensor Adj. Miss. label tol. Sensor Adjust > COM1 PORT Stop count. mode Speed Adaption Baud rate Label stop quan.
1)
Encoder Type No. of data bits
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Encoder Resol. Parity Encoder Diameter Stop bits Tandem Operation Data synch. Tandem Synch. Frame error Tandem Distance Light sens. type > NETWORK PARAM. Labelsen. In.Typ IP Addressassign. Act. apl.interf. IP address Startsen. In.Typ Net mask Start disp. mode Gateway address Start error stop Port address Turn-on mode Ethernet speed Language MAC Address Access authoriz. SNMP Agent Material end err FTP server OD Sensor WEB server
WEB display refr DHCP host name
1) Appears only when LABEL SETUP > Stop count. mode = ‘Enabled’
[24] Function menu ALS20X and ALS256 – Part 1.
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2.4 FUNCTION DESCRIPTIONS
SERVICE/DIAGNOS. SERVICE DATA
Sensor Test Compactflashtest Test functions
> MODULE FW VERS. > MEMORY DATA
System version Ram memory size
> OPERATIONAL DATA Default values Service operations Material feed Dispensing cycl. Operation time
>
POWER SUPPLY DATA
Type
(continued)
Flash mem size
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> CPU BOARD DATA
CPU identifier PCB Revision FPGA version MAC Address Serial number Production date PCB part number Board part numb.
> DISPLAY DATA
Remote Disip. vers
> CF CARD SLOT
Card in slot
> PERIPHERAL DATA
Applicator int.
1) Only with integrated applicator interface.
[25] Function overview in the ALS20x menu – Part 2.
1)
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2.4 FUNCTION DESCRIPTIONS

2.4.2 Notes on function descriptions

These operating instructions only describe those functions that are necessary for operating an ALS20x that has been configured and set up. These functions are highlighted in grey in the function overview.
Only qualified service technicians may change the settings of the other functions. Thes e functions are described in the service manual.
The settings range or the individual settings for a function are shown in square brackets. – The default value is italicised for functions
that have individual settings.
– Settings that consist of several words are
shown in quotation marks.

2.4.3 LABEL SETUP menu

Load prod. profil function:
– Loads product profiles from the internal database. – Produ c t pr of ile s co ntain product-specific settings. – You can select a maximum of 16 product profiles. – You can only select product profile numbers that
have profiles already stored for them.
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Start offset function: – Distance between the product sensor and the top of
the dispensing plate
– Setting range: [15.0…999.9] mm; default: 15.0 Product length function:
– Setting range: [0.0…1999.9] mm; default: 0.0 Miss. label tol. function:
– Missing label tolerance – The maximum permissible number of successive
missing labels on the label strip
– Setting range: [0…10] mm; default: 1 Stop count. mode function:
– Settings: [enabled, disabled]
Enabled: Dispenser counter counts backwards, starting with the value that has been set using the
MACHINE SETUP > Dispense counter function. When the
counter reaches zero, no further labels are dispensed.
Disabled: The dispenser counter counts forwards, which means that the dispenser counter is incremented with each label that is dispensed.
Dispense speed function: – The speed at which the label is dispensed – Setting range:
ALS204: [0.0…40.0]m/min; default: 10.0
ALS206: [0.0…30.0]m/min; default: 10.0
ALS256: [0.0…50.0]m/min; default: 10.0 Slew speed function:
– Feed speed during initialisation – Setting range:
ALS204: [0.0…40.0]m/min; default: 1.0
ALS206: [0.0…30.0]m/min; default: 1.0
ALS256: [0.0…50.0]m/min; default: 1.0 Label pitch function:
– Label pitch = label length+space – Setting range: [5.0…600.0] mm
Lab. stop offset function: – Stop position of the label on the dispensing plate – Setting range: [0.0…999.9] mm; default: 20.0

2.4.4 MACHINE SETUP menu

Start error stop function:
– Determines how the machine responds in the event
of a product start error. A product start err or occurs when a new start signal arrives before the current dispensing cycle has ended.
– Settings: [On, Off]
On: Start errors are issued. If a start error occurs , the device stops and displays a relevant error message. Off: Start errors are ignored.
Turn-on mode function: – The operating mode of the unit after it is turned on. – Settings: [Online, Offline]
Online: Dispensing mode Offline: Configuration mode
Language function: – Language of the displayed text – Settings: [English, French, German, Spanish,
Italian, Dutch, Danish]
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2.4 FUNCTION DESCRIPTIONS

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 th e
left.
£ Press the button to move the text to the
right.
> MODULE FW VERS. submenu
System version function:
– Shows the firmware version of the labeller
> OPERATIONAL DATA submenu
Service operations function:
– Displays the number of service operations that have
been implemented. –
Increment the counter using the
SERVICE/DIAGNOS. > Service function.
– Maximum number: four billion
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MAC Address function: – Displays the MAC address, which is a fixed and
unique board address for the Ethernet interface and is programmed by the manufacturer of the board.
Serial number function: – Displays the serial number that is programmed by
the board manufacturer.
Production date function: – Displays the production date of the CPU board
PCB part number function: – Displays the part number of the unpopulated board.
Board part numb. function: – Displays the part number of the populated board
> DISPLAY DATA submenu
Remote Disp.vers function:
– Displays the version of the external operator panel
Material feed function: – Displays the entire material feed, in other words, the
‘distance covered’ by the drive roller. – Maximum number: four billion metres
Dispensing cycl. function: – Counts the number of dispensed labels.
Operation time function: – Displays the entire on-time
>POWER SUPPLY DATA submenu
Type function:
– Displays the type of power supply
> CPU BOARD DATA submenu
CPU identifier function:
– Displays the identification of the processor in use. PCB Revision function:
– Displays the layout revision and the part number of
the CPU board. FPGA version function:
– Displays the FPGA version.
> CF CARD SLOT submenu
Card in slot function:
– Tests whether the CF card is inserted in the device’s
card slot. – If the result is ‘Yes’, then the CF card is in the slot. – If the result is ‘No’, then there is no CF card in the
slot.
> PERIPHERAL DATA submenu
Applicator int. function:
– The function is only available when an applicator
interface is integrated. – Displays the firmware version of the applicator
interface.
>MEMORY DATA submenu
Ram memory size function:
– Displays the amount of RAM available. Flash mem size function:
– Displays the amount of Flash memory available. Default values function:
– Values that are used for a factory reset (standard or
‘User defined’, s
ee MACHINE SETUP > Default values).
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3.1 ELECTRICAL CONNECTIONS

3 BEFORE OPERATION

3.1 ELECTRICAL CONNECTIONS

3.1.1 Power supply connection

WARNING!
This machine operates using mains voltage! Touching live electrical parts may exp os e you to hazardous electrical currents and may lead to burns.
£ Make sure that the device is switched off
before you connect the power cable.
£ (ALS 20X)Only operate the device with
the mains voltage set on the voltage selector switch.
£ (ALS 20X) Ensure that the unit is set to
receive the mains voltage supplied by your electricity provider.
£ (ALS 256) Only operate the device using
the system voltage indicated on the nameplate.
£ Only connect the unit to a grounded
power socket fitted to authorised standards.
£ The power cable should not be more than
3 m long.
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A
[26] Power supply (A) on the ALS 20X
The device is only completely disconnected from the mains if the power cable is
unplugged. Therefore:
£ Make sure the power supply socket is
accessible.
£ In case of eme rg en c y, sw it ch of f th e
device and disconnect the power cable!
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3.1 ELECTRICAL CONNECTIONS
Checking the power supply setting
ALS256: A power supply setting is not re­quired.
The ALS20X Label Dispenser is suitable for operation with a power supply of 230V (AC) or 110V (AC).
If you are unsure of what mains voltage your local electricity supplier provides, refer to a qualified service technician.
£ Check to see that the voltage that has been set
conforms to the local mains voltage.
Switch setting Permissible mains voltage
115 100–120 V (AC)
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A B
230 200–240 V (AC)
[28] Permissible mains voltages for both positions on the voltage
selector switch.
Changing the voltage setting:
£ Make sure that the power cable is
disconnected.
£ Slide the switch [27A] to the respective
opposite position.
– Insert a small screwdriver into the groove [27B] and
move the red insert horizontally to the opposite stop position (to the left in Figure
[27]).
Connecting the power cable.
£ Make sure that the power switch [29A] is set to ‘O’
(off).
£ Using the supplied power cable, plug the unit into a
socket connected to the mains supply.
For more information on fuses, see section “Replacing fuses” on page 47.
[27] Voltage selector switch on the ALS 20X (set to 230 V in the
figure)
A
B
[29] Power cable (B) plugged in.
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3.1 ELECTRICAL CONNECTIONS

3.1.2 Connecting sensors

£ Check whether the required sensors are connected
before turning on the unit [30].
The minimum required sensors: – Label sensor (installation location: dispensing edge) – Product sensor (installation location: conveyor belt)
Additional optional sensors: – Rotary encoder (required for speed adaption) – External outer diameter checking sensor (provides
advance warning of the end of a label roll)
– Alternative label sensor; for example, capacitive
sensor, used to detect transparent labels.
You can find further information regarding suitable sensor types, pin assignments, and so on in the service manual.
BA
[30] Sensor connectors:
A Label sensor B Product sensor C Optional: Rotary encoder D Optional: Roll diameter check E (ALS20x) Optional: Alternative label sensor F (ALS256) Optional: Alternative label sensor
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C D
EF
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3.2 INSERTING LABEL MATERIAL

3.2 INSERTING LABEL MATERIAL

3.2.1 Prerequisites

– The label dispenser is turned off at the main
switch [31A] (switch set to ‘O’).
£ Check that the safety installations are working
properly.
£ Inspect the machinery for any visible damage.
Report any defects immediately.
£ Remove any unnecessary materials and objects
from the operating area of the unit.
£ Make sure that only authorised persons are within
the operating range of the machine.
£ Use the required personal protective equipment
correctly; forexample, wear a hairnet, safety glasses.
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A
[31] Main switch on the housing.
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3.2 INSERTING LABEL MATERIAL

3.2.2 Inserting a label roll

WARNING!
Risk of injury due to moving and rapidly rotating parts!
£ Before inserting the label roll, ensure that
the device is turned off at the main switch.
£ Do not under any circumstances turn the
device on before the label strip is threaded in completely.
Removing spent backing paper
Assuming backing paper has gathered on the rewinde r [32A] :
£ Press the release button [32B].
– The tensioning mechanism of the rewinder is
slackened.
£ Remove the rewound backing paper.
A
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B
Removing glue residue
£ If necessary, clean the following components:
– Dispensing plate – Deflection rollers – Drive rollers – Pressure roller
£ Follow the directions provided in section
“Maintenance and cleaning” on page 47.
Inserting a new label roll
£ Push the material roll [33A] onto the unwinder as far
as it will go.
£ Rotate the rotary knob [33B] in a clockwise direction
until the label roll sits tightly.
£ Run the label strip around the dancer arm as shown
in the figure [33C].
[32] A Rewound backing paper
B Release button C Backing paper path
B
A
C
[33] Inserting the material roll – Part 1.
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3.2 INSERTING LABEL MATERIAL

3.2.3 Threading the label roll Threading guide

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[34] Threading guide for label rolls with labels facing outwards.
A Right-handed version B Left-handed version
BA
BA
[35] Threading guide for label rolls with labels facing inwards.
A Right-handed version B Left-handed version
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3.2 INSERTING LABEL MATERIAL
Threading the label roll at the dispensing edge
£ Unroll around 1m of label strip and remove the
labels from it.
£ Pass the backing paper around the first deflection
roller [36A] and through the slot in the sensor [36B].
£ Feed the backing paper under the pressure roller
[36C] to the dispensing plate [36D].
£ Feed the backing paper around the dispensing plate
to the second deflection roller [36E].
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A
B
C
E
[36] Path of the label strip at the dispensing edge.
A 1st deflection roller B Label sensor C Pressure roller D Dispensing plate E 2nd deflection roller
D
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3.2 INSERTING LABEL MATERIAL
Threading the label roll onto the drive roller
£ Open the pressure roller. To do so, rotate the lever
[37D] in a clockwise direction.
£ Feed the backing paper around the deflection roller
[37B], drive roller [37C] and the dancer arm [37A].
£ Close the pressure roller. To do so, rotate the lever
until it snaps in noticeably.
A
D
[37] Open the pressure roller.
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B
C
Fastening the label roll to the rewinder
£ Clamp the backing paper to the rewinder as shown
and tighten it [39].
£ Manually rotate the rewinder by one turn.
[38] Close the pressure roller.
[39] Fastening the backing paper to the rewinder.
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3.3 MECHANICAL SETTINGS

3.3 MECHANICAL SETTINGS

3.3.1 Adjusting the unwinder’s core
diameter
Tool: – 3 mm hexagon (Allen) screwdriver
The unwinder can be adjusted with core adapters [40B] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter:
– 38.1mm (1”) core
£ Unscrew the screws [40A] (3 for each adapter) and
remove the adapters.
– 76.2mm (3”) core
£ Screw on the adapters, as is shown in Figure [40].
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B
A
[40] Core adapter positions for a core diameter of 76.2mm.
– 101.6 mm (4”) core
£ Screw on the adapters, as is shown in Figure [41].

3.3.2 Positioning the pressure roller

£ Open the pressure roller [42B]. To do so, rotate the
lever [42C] until the roller snaps up.
£ Release thumb screw [42A]. £ Align the pres su re rolle r over th e ba ckin g pap er so
that it is centred.
£ Close the pressure roller. £ Screw the thumb screw tight.
[41] Core adapter positions for a core diameter of 101.6mm.
B
C
A
[42] Setting the position of the pressure roller (B).
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3.3 MECHANICAL SETTINGS

3.3.3 Positioning the label sensor

£ Release the thumb screw. £ Position the sensor along the axle in such a way as
to allow it to register the spaces between the labels.
The LED [43A] lights up when the sensor is positioned over a label.
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B
A
[43] Label sensor from Wenglor, model OPT242-P800
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4.1 START-UP AND SHUTDOWN

4 OPERATION

4.1 START-UP AND SHUTDOWN

4.1.1 Turning on the unit

£ Set the main switch [44A] of the unit to ‘I’ (On).
– The following messages are displayed during the
start process:
ALS204 RH:
V 1.00
(machine type and firmware version)
Memory: 16 MB Flashcard 48 MB
(the machine’s RAM, as well as the CF card’s memory, if a card is inserted)
ONLINE
Label 0
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A
[44] Main switch (A) of the ALS 20x
– Once switched on, the ALS20x is in dispensing
mode; in other words, triggering the product sensor will cause a label to be dispensed.
– You can find more information on the dispensing
mode in the section “Spendebetrieb” on page 18.

4.1.2 Starting label dispensing

Dispensing with a product sensor
Once switched on, the ALS20x is in dispensing mode; this means that triggering the product sensor will cause a label to be dispensed.
Prerequisites: – The label length must be specified. – The product sensor must be connected.
– The sensors must be configured correctly
(PNP/NPN).
Dispensing without a product sensor
It is also possible to trigger the dispensing process without a product sensor:
– The machine is in dispensing mode:
£ Press the button.
– The machine is in configuration mode:
£ Press the button briefly (less than two
seconds).
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CONTENTS
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4.1 START-UP AND SHUTDOWN
4.1.3 Stopping the dispensing
process
– The machine is in dispensing mode:
£ Press the button.
– Display:
ONLINE
Stopped: xxx – The dispenser stops.
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4.2 CONFIGURATION AND MONITORING

4.2 CONFIGURATION AND MONITORING

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 pitch function. £ Enter the measured value in millimetres.
[45] A Label web
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AB
C
B Label C Label pitch
Label stop position
Prerequisites: – The label length must be specified.
The next label to be dispensed waits in the label stop position. Here it is useful if the label protrudes over the dispensing edge a little [46].
ALS20X and ALS 256 labellers are pre­configured for use with the supplied label sensor. If this sensor is employed, the label stop position setting will only require minimal correction.
Correcting the default setting:
£ Call the LABEL SETUP > Lab. stop offset function.
£ Increase the value to increase the overhang or
lower the value to reduce the overhang.
The value ‘0’ will cause the label to stop with its front edge directly under the label sensor.
The front edge of the next label to be dispensed sh ould be flush with the dispensing edge:
£ Enter the distance [46A] between the label sensor
and the dispensing edge.
A
[46] Label stop position (A)
The front edge of the label to be dispensed should overhang:
£ Add the length of the overhang to the distance
between the label sensor and the dispensing edge.
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CONTENTS
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4.2 CONFIGURATION AND MONITORING
Dispensing speed
You can set the dispensing speed to a fixed value or you can configure it to automatically 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 conveyor speed to the dispenser.
Configuring a fixed value:
£ Use the two left buttons to set the speed in
dispensing mode (online settings) (see “Online settings” on page 22).
Or use the function menu settings:
£ Call the LABEL SETUP > Dispense speed function and
set the speed you require.
Configuring speed adaption:
£ Turn the function on by setting MACHINE SETUP >
Speed Adaption to ‘Yes’.
£ Set MACHINE SETUP > Encoder Resol. and
MACHINE SETUP > Encoder Diameter as
appropriate for the employed rotary encoder.
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– See the service manual for information on suitable
rotary encoders.
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4.2 CONFIGURATION AND MONITORING
Label position on the product
Prerequisites: – The label length must be specified. – The label stop position must be set.
Configuration in dispensing mode:
£ Use the two right buttons to set the start offset (see
“Online settings” on page 22).
Or use the function menu settings:
£ Call the LABEL SETUP > Start Offset function and set the
start offset.
– The label should be flush with the front edge of the
product:
£ Enter the distance between the product sensor and
the dispensing edge [47A].
[47] Distance between the product sensor (left) and the
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A
dispensing edge (right).
– The label sh ou ld be stuc k at a dist an ce fro m the
front edge of the product:
£ Increase the start offset by the distance [48A] to the
product’s front edge.
A
[48] Distance (A) between the label and the product’s front
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4.2 CONFIGURATION AND MONITORING

4.2.2 Monitoring functions

While in dispensing mode, an electronic controller monitors the following functions:
Missing labels
A label missing from the label roll does not normally affect the dispensing operation, because the label feed continues until a label’s edge passes under the label sensor.
Nonetheless, it can be important that missing labels are reported. By configuring the function LABEL SETUP >
Miss. label tol., you can specify whether an error message
is triggered after one or several missing labels.
Material end
Material tear
If the material path tears, one of these two messages appears:
Status num: 5002 Material end
Status num: 5140 Rewinder control
– Which message appears depends on where the
material path is torn.
– The machine stops.
£ Press the button.
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The following message appears when the material roll is empty:
Status num: 5002 Material end
– The machine stops.
£ Press the button to delete the message. £ Remove the rewound backing paper. £ Insert a new material roll (see “Inserting label
material” on page 32).
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4.3 USING PRODUCT PROFILES

4.3 USING PRODUCT PROFILES

4.3.1 What are product profiles?

Product profiles are memory locations that can store all the settings for the machine controls. For recurring production jobs, they allow you to quickly set the machine to the respective product.
– Number of memory locations: 16 – The memory locations are numbered. In addition,
you can also enter a text identifier for each memory location (with a maximum of eight alphanumeric characters).

4.3.2 Loading a product profile

CAUTION!
Incorrect settings may lead to production problems and damage both the unit and the equipment.
£ Only staff who are qualified and specially
trained should set up product databases.
£ Call the LABEL SETUP > Load prod. profil function.
– The following message appears when no memory
location is occupied:
Load prod. profil No setup avail.
– Only occupied memory locations are displayed. – When memory locations are occupied, the memory
location that was loaded last is displayed first:
Load prod. profil Prof 1 xxxxxx
Above example: The profile with the ‘xxxxxx’ text identifier has been stored at the first memory location.
£ Press the or the button until the profile you
require appears.
£ Press the button to load the profile.
– The unit restarts afterwards. – Display after the restart:
Prof 1 xxxxxx Label 0
(in dispensing mode, ‘ONLINE’ is replaced by the current profile name).
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4.3.3 Storing a product profile

Selecting the memory location
£ Call the MACHINE SETUP > Store prod.prof. function.
– Display shown when all memory locations are
unoccupied:
Store prod.prof. Prof 1 Product 1
– When memory locations are already occupied, the
memory location that was last active is displayed:
Store prod.prof. Prof 5*customer_xyz
– A ‘*’ occurring after the memory location number
indicates that the memory location is already
occupied (here by the ‘customer_xyz’ profile ) .
£ Press the or the button until you retrieve the
memory location you require (1–16).
£ Press the button to activate the memory
location.
– The profile name flashes, and you can now replace
the name using any text you choose.
Entering profile names
Accepting the profile name ‘Product 1’ without changing it:
£ Press the button twice.
– The profile is saved. – Display:
Store prod.prof. Storing…
Changing a profile name:
£ Press the button.
– Display:
Store prod.prof. Prof x _
– The underscore marks the active position.
£ Press the or the button to scroll through the
available characters until the character you require
appears.
£ Press the button to accept the character.
– The underscore jumps to the next character.
£ Enter the next character in the same way. £ When you have entered the last character, press the
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CONTENTS
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4.3 USING PRODUCT PROFILES
button. – The profile is saved. – Display:
Store prod.prof. Storing…
– The product profile has now 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 retrieve the
memory location you require (1–16).
£ Press the button to delete the memory location:
– Display:
Del prod.profil Clearing…
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– The product profile has now been deleted.
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5.1 MAINTENANCE AND CLEANING

5 AFTER OPERATION

5.1 MAINTENANCE AND CLEANING

5.1.1 Replacing fuses

This section counts only for ALS20X. The fu­ses at the ALS256 cannot be replaced.
WARNING!
The machine operates using mains voltage!
Touching live electrical parts may exp os e
you to hazardous electrical currents and
may lead to burns.
£ Make sure that the machine is switched
off and the power cable is unplugged before removing the fuse insert.
CAUTION!
Risk of fire, if a wrong fuse type is inserted.
£ Only replace fuses with the type and
rating specified in this manual.
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Tool: Screwdriver
£ Turn off the unit. Unplug the power cable. £ Rotate the fuse holder a few degrees anticlockwise.
– The fuse holder pops up.
£ Take the fuse out of the fuse holder. £ Replace defective fuse. £ Replace the fuse holder and rotate it clockwise,
while applying light pressure, until the slot is vertically positioned.
Required fuse type: – T5AH 250V
The F1 and F2 fuses protect the primary side of the transformer. At any given time, only one of the two fuses is active. Which fuse is active depends on the switch setting of the voltage selector switch.
Active fuse Mains voltage Switch setting
F1 230V 230 F2 110V 115
[49] Relation between the switch setting of the voltage selector
switch and the active fuse.
The CPU board and sensors are protected by a separate fuse in the switching power supply that must/may never be replaced.
If either of the two fuses is not working properly, only the drive motors are affected; the display and sensors continue to operate as normal.
A
[50] Fuse holder (A) of the ALS 20x.
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5.1 MAINTENANCE AND CLEANING

5.1.2 Cleaning agents

Cleaning agents for rubber rollers:
– Roller cleaner, order number 98925.
If other cleaning agents are used, there is a chance the rubber may corrode.
Cleaning agents for metal deflection rollers:
– Cleaning solvent, alcohol-based solvent,
isopropyl alcohol, spray for removing labels
Cleaning the unit’s housing:
– Commercially available neutral cleaning
liquid
WARNING!
Cleaning solvent, alcohol-based solvent an d
isopropyl alcohol are highly inflammable!
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£ Keep the cleaning agents, as well as any
used cleaning cloths, away from open flames and other sources of ignition.
£ Do not smoke.
£ Observe the safety instructions on the
container.
CAUTION!
Unsuitable cleaning agents can cau s e
considerable damage to the unit!
£ Do not use any cleaning agent that could
damage or destroy the resin surface, labelling, display, nameplates, electrical components, etc. Observe the instructions of the cleaning agent manufacturer.
£ Do not use any abrasive or
plastic-corroding cleaning agents.
£ Do not use any acidic or alkaline
solutions.
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5.1 MAINTENANCE AND CLEANING

5.1.3 Regular maintenance

The label dispenser is designed to be maintenance-free. However, you should service the unit regularly in order to ensure reliable long-term operating results.
Depending on operating conditions, you should perform the following at least once a week:
£ Carry out the cleaning and maintenance work
described below.
Removing paper debris
£ Wipe the paper residue from the rollers and edges. £ Clean the sensor lenses with a soft brush or cloth.
Renewal of the dust filter liner (ALS256)
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CAUTION!
An exhausted filter liner can cause the
machine to overheat and to break down.
£ Replace the filter liner regularly, at least
in monthly intervals.
In case of overheating the machine, the error message „5026 MotorProtect CPU“ appears, see “List of error messages” on page 50.
£ Screw out the four thumb screws [51A]. Remove the
filter cover [51B].
£ Replace filter liner (article no. A8697). £ Assemble the filter cover and fix it using the thumb
screws.
A
A
[51] Dust filter at an ALS256.
A Thumb screws B Filter cover
B
A
A
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6.1 ERROR MESSAGES

6 OPER ATIONAL FAILURES

6.1 ERROR MESSAGES

6.1.1 Reporting errors

When an error occurs, the machine stops immediately and displays an error message on the control panel.
Error messages are displayed as follows:
Status num: 5144 Rewinder init20x 256
[52] An example of an error message:
5144 = status number; this number makes it easier to identify the message. ‘Rewinder init’ = status text; a brief description of the error.

6.1.2 List of error messages

Status Status text Cause A ction to take
Error messages that are not described here may only be resolved by a qualified service technician.
When an error occurs that is not described here:
£ Press the button to delete the message. £ Switch the device off, wait 30 seconds and then
switch it on again.
If the error reoccurs:
£ Request a service technician.
Error messages that are not mentioned here are described in the service manual.
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5000 Bus device – Device at I2C Bus cannot be contact-
ed.
– In most cases, this message appears
as the first in a series of two or three messages which narrow down the er­ror more precisely.
5001 No gap found – The maximum limit for missing labels
was exceeded (LABEL SETUP > Miss. la-
bel tol.).
– The machine is not correctly set for
the type of label (MACHINESETUP >
Light sens. type ).
– Label length is not correctly set
(LABEL SETUP > Label distance). – Photoele ct ric lab e l sens or is dirty. – Photoele ct ric lab e l sens or is incor -
rectly positioned. – Photoelectric label sensor is not con-
nected correctly. – Photoele ct ric lab e l sens or is defe c-
tive. – Rotary encoder is not adjusted cor-
rectly.
£ Delete the me ss ag e by pre ssin g the
-key.
£ Switch the machine off, wait 30 sec-
onds and switch it back on.
£ If the error message
appears re­peatedly, call in a servicing tech­nician.
£ Check the points listed above and
correct if necessary.
£ Press the key to confirm the er-
ror message.
5002 Rewinder full The (internal) roll diameter control has
calculated that the end of the material roll has been reached.
[53] List of error messages
50
£ Insert new label roll.
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6.1 ERROR MESSAGES
Status Status text Cause A ction to take
5026 MotorProtect CPU – (ALS256) Dust filter liner exhausted.
This leads to overheating the ma­chine.
– (ALS 20X) Voltage selection switch
set faulty.
– There are some more possible caus-
es, which require a qualified service technician to cure.
5140 Rewinder control Rewinder control
During problem-free operation, the rewind unit dancer arm only moves a minimal distance around the "control position". This is the position the dancer arm takes up after initialisation of the machine.
£ Renew the dust filter liner.
£ Check setting of the voltage selectio-
in switch.
£ If none of the above listed actions is
successful, search for technical as­sistance.
£ Press the key.
– This reinitialises the dancer arm con-
trol; the dancer arm moves back into the control position.
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– Any force applied that moves the
dancer arm from its control position. Example: The feed motor is blocked;
the backing paper is not conveyed quickly enough; as a result the dancer arm is pulled upwards.
Example: The backing paper is torn; the dancer arm springs downwards.
5143 Rewinder Stop – This message appears when the
dancer arm was held against its up­per stop for more than two seconds.
Effect: Power to the rewinder motor is switched off, so that the rewinder can be turned easily by hand.
This effect is helpful when in­stalling a new label roll, because the rewinder can be turned easily.
5145 Material feed Th e ma xim u m pe rm itt ed dia me te r
(205mm) for the rewinder roll has been reached.
£ Press the key to confirm the er-
ror message.
£ Remove the rewound backing paper
This error can only occur if the end of a new label roll was glued on to backing paper that had al­ready been wound onto the re­winder.
[53] List of error messages
£ Press the key to confirm the er-
ror message.
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6.1 ERROR MESSAGES
Status Status text Cause A ction to take
5147 Tandemsynch. Init This message can only appear
during tandem operation.
– Communication between the master
and slave machines is not function­ing.
5200 Home position This message may appear when
operating the applicator. The ap­plicator did not reach its home position (upper end position) within the intended time-frame.
– The applicator is stuck – Compressed air applicator: Com-
pressed air supply interrupted or switched off
– Cable not correctly connected.
£ Check tandem interface cable.
– Is it a) in place and b) correctly con-
nected?
£ Check the settings on both ma-
chines.
– Siehe “Setting up tandem operation”
auf Seite 112.
£ Remove any obstructions £ Check compressed air connection
and reconnect correctly if necessary
£ Check cable and connect correctly if
necessary.
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5201 Touch Down The applicator lower end position
(Touch Down) was not reached in time.
6002 New prog. vers. New firmware has been loaded. This is a
message from the labeller that new firmware is available.
6031 New Parameters New firmware was loaded with the result
that new functions have been added to the menu.
6207 No file card No compact flash card was found. £ Check whether a compact flash card
9022 No network link This status me ssage can only appear
when Ethernet address assignment is set to DHCP (INTERFACE PARA >
NETWORK PARAM.> IP Addressassign). The
cause is almost invariably an incorrectly plugged-in network connector.
[53] List of error messages
£ Press the Online button to confirm.
– All parameters are reset to their fac-
tory settings.
£ No action necessary. The message
is for information only.
is connected. If the compact flash card was not connected until after the machine was switched on: Switch the machine off and back on again.
£ Check whether the network connec-
tor is plugged in correctly, correct if necessary.
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7.1 EU DECLARATION OF CONFORMITY
256

7 APPENDIX

7.1 EU DECLARATION OF CONFORMITY

We,
Avery Dennison Deutschland GmbH Ohmstrasse 3
85386 Eching, Germany
herewith assert that we have designed and built the device described in the following to conform with the basic safety and health requirements of the relevant EU directives.
Name of the devices: ALS 204, ALS 206, ALS 256 Device type: Label dispenser Serial number: Consists of a sequential number (five-digit) +
date code (YYMM) + ending (device name): –ALS204, –ALS206 or –ALS256
(Example: 040060309–ALS204)
GB
Relevant EU directives: 89/336/EEC (EMC Directive)
73/23/EEC (Low Voltage Directive)
Other applicable, harmonised norms, in particular:
Eching, 21 March 2006
EN 60950-1: 2001 + A11 (Information technology equipment safety) EN 55022:98 + A1:2000 + A2:03 (Information technology equipment ­Radio disturbance characteristics - Limits and methods of measurement ) EN 61000–6-2: 2001 (Immunity standard for industrial environments) EN 61000-3-2: 2000 (Limits for harmonic current emissions) EN 61000-3-3: 1995 + A1:2001 (Limitation of voltage changes, volta ge fluctuations and flicker)
Markus Roderer (General Manager)
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Avery Dennison Deutschland GmbH
Ohmstrasse 3 85386 Eching Germany Phone: +49-8165-925-0 http://www.machines.averydennison.com
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