Avery ALS 380 User Manual

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OPERATING MANUAL

Label Dispenser

ALS

380

Article number: A6392, Release 06.2005

Page 2

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CONT ENTS

CONTENTS

ALS

380

1 Please observe the following

1.1 General information . . . . . . . . . . . . . . 4

1.1.1 Validity and applicability of this manual . . . . . 4

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical State . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1.2 Conventions and information . . . . . . . . . . . . . 5

Explanation of symbols . . . . . . . . . . . . . . . . . . . . 5

Warnings concerning dangers and risks . . . . . . . 5

Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Supplemental information . . . . . . . . . . . . . . . . . . 5

Directional information. . . . . . . . . . . . . . . . . . . . . 6

1.2 Safety instructions . . . . . . . . . . . . . . . 7

1.2.1 Information and qualifications . . . . . . . . . . . . . 7

Pay attention to the information. . . . . . . . . . . . . . 7

Information must be made available . . . . . . . . . . 7

Ensure necessary qualifications . . . . . . . . . . . . . 7

1.2.2 Machine operating safety . . . . . . . . . . . . . . . . 8

Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Protect against injuries that can result from

electrical current . . . . . . . . . . . . . . . . . . . . . . . . . 8

Protect against injuries that can result from

mechanical actions . . . . . . . . . . . . . . . . . . . . . . . 8

Protection against chemicals. . . . . . . . . . . . . . . . 8

1.2.3 Before every production start . . . . . . . . . . . . . 9

Operator's obligation and service personal to

exercise care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating personnels' obligation to exercise

care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Equipment description

2.1 Overview . . . . . . . . . . . . . . . . . . . . . 10

2.1.1 Structural elements . . . . . . . . . . . . . . . . . . . . 10

2.1.2 Principle of operation . . . . . . . . . . . . . . . . . . 11

2.1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . 12

Characteristic values . . . . . . . . . . . . . . . . . . . . . 12

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . 12

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . 12

Control system . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 13

Top-labeller right-hand version . . . . . . . . . . . . . 13

Side-labeller right-hand version. . . . . . . . . . . . . 13

Top-labeller left-hand version . . . . . . . . . . . . . .14

Side-labeller left-hand version . . . . . . . . . . . . . .14

2.1.5 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

High-speed processing version ALS 380 HS . .15

Serial interface. . . . . . . . . . . . . . . . . . . . . . . . . . 15

Roll diameter control . . . . . . . . . . . . . . . . . . . . . 15

Adjustable dispensing edge. . . . . . . . . . . . . . . . 15

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Operator controls . . . . . . . . . . . . . . . 16

2.2.1 Operator panel . . . . . . . . . . . . . . . . . . . . . . . 16

LED indicator . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2.2 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Control system . . . . . . . . . . . . . . . . . 18

2.3.1 Brief description . . . . . . . . . . . . . . . . . . . . . . 18

2.3.2 Menus for operators and calibration

technicians . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3.3 Monitoring functions. . . . . . . . . . . . . . . . . . . 20

Dispensing a label to each product . . . . . . . . . .20

Label supply . . . . . . . . . . . . . . . . . . . . . . . . . . .20

If errors occur . . . . . . . . . . . . . . . . . . . . . . . . . .20

3 Prior to operating

3.1 Insert the labelling material . . . . . . . 21

3.1.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1.2 Insert the label roller. . . . . . . . . . . . . . . . . . . 21

Remove the old backing material . . . . . . . . . . .21

Remove adhesive residues . . . . . . . . . . . . . . . .21

Insert new label roll . . . . . . . . . . . . . . . . . . . . . . 22

3.1.3 Threading the label ribbon . . . . . . . . . . . . . . 23

Overview of the threading path diagram . . . . . . 23

Thread the label ribbon at the unwind unit. . . . .24

Thread in the label ribbon at the dispensing

edge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Thread the label ribbon at the rewind unit. . . . .26

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CONTENTS

ALS

380

3.2 Mechanical settings . . . . . . . . . . . . . 27

3.2.1 Setting the ribbon guides . . . . . . . . . . . . . . . 27

Operator panel support . . . . . . . . . . . . . . . . . . . 27

Deflection rollers on the rewind unit . . . . . . . . . 27

3.2.2 Adjusting the braking brushes. . . . . . . . . . . . 28

3.2.3 Adjusting the pressure rollers . . . . . . . . . . . . 29

3.2.4 Adjust the pressure roller unit (optional) at

the dispensing edge.. . . . . . . . . . . . . . . . . . . 30

3.2.5 Adjust (optional) the position of the

dispensing edge.. . . . . . . . . . . . . . . . . . . . . . 31

Adjusting vertically. . . . . . . . . . . . . . . . . . . . . . . 31

4 Operation

4.1 Activation and shut-down. . . . . . . . . 32

4.1.1 Starting the machine . . . . . . . . . . . . . . . . . . . 32

Automatic material initialisation . . . . . . . . . . . . . 32

Manually initialise the material . . . . . . . . . . . . . 33

4.1.2 Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Start dispensing labels . . . . . . . . . . . . . . . . . . . 35

Unwind unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Rewind unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.1.3 Stop/end the label dispensing. . . . . . . . . . . . 36

4.1.4 Tandem operation. . . . . . . . . . . . . . . . . . . . . 37

Principle of operation. . . . . . . . . . . . . . . . . . . . . 37

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Start dispensing labels . . . . . . . . . . . . . . . . . . . 38

Reloading label material . . . . . . . . . . . . . . . . . . 39

Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2 Setting and monitoring. . . . . . . . . . . 41

4.2.1 Settings in the standard menu . . . . . . . . . . . 41

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Calling up menu . . . . . . . . . . . . . . . . . . . . . . . . 41

Call up function . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.2.2 Label stop position (STOD). . . . . . . . . . . . . . 42

4.2.3 Dispensing speed (VELO) . . . . . . . . . . . . . . 43

Automatic dispensing speed (optional) . . . . . . . 43

4.2.4 Label position on the product (POS). . . . . . . 44

4.2.5 Automatic material initialisation (INIT) . . . . . 45

4.2.6 If errors occur . . . . . . . . . . . . . . . . . . . . . . . . 46

4.3 Product databanks . . . . . . . . . . . . . . 48

4.3.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3.2 Loading product data banks. . . . . . . . . . . . . 48

Please observe:. . . . . . . . . . . . . . . . . . . . . . . . . 48

Activating product databanks at switch-on . . . .49

Activating product databanks after switch-on . .49

4.3.3 Create/save product databank . . . . . . . . . . . 50

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Saving the product databank. . . . . . . . . . . . . . .50

Documenting product databanks. . . . . . . . . . . . 50

4.3.4 Deleting a product databank . . . . . . . . . . . . 51

4.4 Settings in the extended menu. . . . . 52

4.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.4.2 Activating an extended menu. . . . . . . . . . . . 54

Please observe:. . . . . . . . . . . . . . . . . . . . . . . . . 54

Calling up menu. . . . . . . . . . . . . . . . . . . . . . . . . 54

Call up function . . . . . . . . . . . . . . . . . . . . . . . . . 54

Exit the extended menu. . . . . . . . . . . . . . . . . . .54

4.4.3 Position of second label (POS2) . . . . . . . . . 55

4.4.4 Position of third label (POS3). . . . . . . . . . . . 55

4.4.5 Speed ratio (VERT) . . . . . . . . . . . . . . . . . . . 56

4.4.6 Adjust the label stop sensor (CONT) . . . . . . 57

Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Automatically adjusting the photoelectric

sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Manually adjusting the sensor. . . . . . . . . . . . . .58

4.4.7 Label distance (LPIT) . . . . . . . . . . . . . . . . . . 59

Check setting. . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.4.8 Distance from the label stop sensor to the dis-

pensing edge (E–SS) . . . . . . . . . . . . . . . . . . 60

Set distance. . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Check setting. . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.4.9 Product length (PRDL) . . . . . . . . . . . . . . . . . 62

4.4.10 Polarity of the product sensor (P_S_) . . . . . 63

4.4.11 Polarity of the label stop sensor (S_S_). . . . 63

4.4.12 Number of unlabelled products (MLAB) . . . . 64

4.4.13 Electronic transmission ratio of the

RPM transmitter (EGRA) . . . . . . . . . . . . . . . 64

4.4.14 Advance print start (PDT). . . . . . . . . . . . . . . 65

4.4.15 Printer dwell time (PDWT) . . . . . . . . . . . . . . 65

4.4.16 Tandem operation (TMOD) . . . . . . . . . . . . . 66

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CONTENTS

ALS

380

4.4.17 Applicator type (APPL) . . . . . . . . . . . . . . . . . 66

4.4.18 EP cylinder dwell time (APT1) . . . . . . . . . . . 66

4.4.19 Blowing time (APT2) . . . . . . . . . . . . . . . . . . . 66

4.4.20 Delay time (APT3). . . . . . . . . . . . . . . . . . . . . 66

4.4.21 Fine tuning of the dwell time (APT4). . . . . . . 66

4.4.22 Delete a product data bank load (LOAD) . . . 66

4.4.23 Create/save product data bank (SAVE) . . . . 66

4.4.24 Delete a product data bank (DEL) . . . . . . . . 66

4.5 Automatic dispensing speed

(APSF). . . . . . . . . . . . . . . . . . . . . . . 67

4.5.1 Electronic transmission ratio of the

RPM transmitter (EGRA) . . . . . . . . . . . . . . . 68

Setting the compensation factor . . . . . . . . . . . . 68

Test the setting:. . . . . . . . . . . . . . . . . . . . . . . . . 68

4.6 Applicator (optional). . . . . . . . . . . . . 69

4.6.1 Principle of operation . . . . . . . . . . . . . . . . . . 69

4.6.2 Functions in the extended menu. . . . . . . . . . 70

Please observe the following. . . . . . . . . . . . . . . 70

Calling up the extended menu. . . . . . . . . . . . . . 70

Applicator type (APPL) . . . . . . . . . . . . . . . . . . . 70

EP cylinder dwell time (APT1). . . . . . . . . . . . . . 71

Blowing time (APT2) . . . . . . . . . . . . . . . . . . . . . 71

Delay time (APT3) . . . . . . . . . . . . . . . . . . . . . . . 71

Fine tuning of the dwell time (APT4) . . . . . . . . . 72

5 After operation

5.1 Care and cleaning . . . . . . . . . . . . . . 73

5.1.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . 73

5.1.2 Regular maintenance . . . . . . . . . . . . . . . . . . 73

Remove paper waste. . . . . . . . . . . . . . . . . . . . . 74

Braking brushes. . . . . . . . . . . . . . . . . . . . . . . . . 74

Capacitive sensor at the dispenser head . . . . .75

6 Operational malfunctions

6.1 Warning messages. . . . . . . . . . . . . . 76

6.1.1 Please observe: . . . . . . . . . . . . . . . . . . . . . . 76

6.1.2 If a problem occurs. . . . . . . . . . . . . . . . . . . . 76

6.1.3 Warning messages . . . . . . . . . . . . . . . . . . . 76

6.2 Error messages . . . . . . . . . . . . . . . . 78

6.2.1 If a malfunction occurs . . . . . . . . . . . . . . . . . 78

6.2.2 Error codes. . . . . . . . . . . . . . . . . . . . . . . . . . 78

7 Appendix

7.1 Factory settings . . . . . . . . . . . . . . . . 82

7.2 Product data banks . . . . . . . . . . . . . 84

7.3 EC Declaration of Conformity. . . . . . 86

Page 6

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

1 PLE ASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

1.1.1 Validity and applicability of this manual

ALS

380

The present manual refers exclusively to the ALS 380 Labeller and the high-speed ALS 380 HS version. The manual is to be referred to for correct operation and adjustment of the machine.

The prerequisites for operation and adjustment are proper installation and configuration of the machine.

For technical questions which are not addressed in this operating manual:

➔ Refer to the Service Guide for the ALS 380 Labeller

➔ consult the servicing technician of our sales partner.

– The responsible servicing technician of our sales

partner is at your disposal and particularly helpful with configuration settings and remedying malfunctions.

Technical State

Technical state as of: 06/2005

Software versions ALS 380: 6.1 ALS 380 HS: Master 1.1, Slave 1.0

Copyright notice

All rights to this operating manual are assigned to Avery Dennison. Transmission, reprinting or any other means of reproduction of this manual, whether whole or in part, are not allowed without prior written permission. Third parties, in particular competitors, are not to be allowed access to information derived from this manual.

Printed in Germany

Manufacturer

Avery Dennison Deutschland GmbH Ohmstraße 3 D - 85386 Eching Phone: +49-8165-925-0 FAX: +49-8165-3143 http://www.machines.averydennison.com

Avery Dennison reserves the right to: – implement modifications of structural parts, compo-

nents and software as well as to use equivalent components that keep pace with the current state of

technology in lieu of the specified components. – change information contained in this manual. An obligation to extend these modifications to previously delivered machines is excluded.

Page 7

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

1.1.2 Conventions and information

ALS

380

Explanation of symbols

In order to facilitate legibility and an overview, the various types of information used herein are categorised and identified with certain symbols.

Sentences that are introduced by an arrow contain procedural instructions.

➔ Carry out procedural instructions one after the other

in the prescribed order.

The following information is introduced with a dash: – List items – Descriptions of conditions – Description of previous work steps – Prerequisites for implementing actions described in

the following passage

Warnings concerning dangers and risks

Important text passages which must absolutely be followed are particularly marked for special attention:

DANGER!

A danger notice indicates an imminent hazardous situation which, if not avoided, could result in death or serious injury of the personnel! The notice contains instructions on how to avoid or prevent the danger(s).

➔ The instructions must be followed.

Illustrations

When required, text passages are accompanied by illustrations. The reference to an illustration is indicated by typesetting the [illustration number] in square brackets. Capital letters following an illustration number, e.g. [12A], refer to the corresponding position indicated in the illustration.

Supplemental information

The "Experts" symbol earmarks activities that only to be performed by knowledgeable and trained personnel.

The information symbol indicates notices and recommendations as well as additional helpful information.

Operating materials: – Operating materials, e.g. lubricants or

cleaning agents

WARNING!

A warning notice indicates risks which could result in death or serious injury of the personnel! The notice contains safety instructions on how to safeguard possibly affected personnel.

➔ The instructions must be followed.

CAUTION!

A caution notice indicates risks which, if unheeded, could lead to material damage or bodily injury (minor injuries). The notice contains instructions on how to prevent damage or injury.

➔ The instructions must be followed.

Page 8

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

ALS

380

Directional information

Unless otherwise indicated, the directional information mentioned in the text refers to the construction of the right-hand version of Top Labeller. See Figure [1] for the explanation of directional information.

[1] Definition of directional information

A Front B Rear C Upward D Downward E Left F Right G Clockwise H Counter-clockwise

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1PLEASE OBSERVE THE FOLLOWING:

1.2 S

1.2 SAFETY INSTRUCTIONS

1.2.1 Information and qualifications

AFETY INSTRUCTIONS

ALS

380

Pay attention to the information

WARNING!

Reliable and safe operation of the labeller is only guaranteed if all necessary information is observed!

➔ Read this operating manual thoroughly

and observe all notices prior to operation.

➔ Observe all additional safety and warning

notices attached to the labeller.

➔ Only allow qualified persons to operate

and adjust the labeller.

Information must be made available

This operating manual

➔ is to stored at the machine operating location and

made accessible to the operator.

➔ is to maintained in legible condition. ➔ is to be made available to the new owner if the ma-

chine is sold.

➔ Safety and warning notices attached to the labeller

must be kept clean and legible. Missing or damaged

warning labels and plates are to be replaced.

Ensure necessary qualifications

➔ Only allow the machine to be operated, adjusted

and serviced by instructed and authorised personnel.

➔ Adjustment tasks via the expanded menus as well

as programming and administration of product databases are only to be performed by qualified and appropriately trained personnel or by the responsible servicing technician.

➔ The responsibilities for operation, adjustment and

servicing of the machine must be clearly defined and consistently maintained.

➔ Moreover, personnel are to be regularly instructed

about work safety and environmental protection issues.

Operator qualifications

Instruction of the operating personnel must ensure: – that operating personnel can use the machine inde-

pendently and without posing a danger.

– that operating personnel can remedy minor opera-

tional malfunctions themselves.

➔ Train at least 2 person to operate the machine. ➔ Make label materials for test purposes available in

sufficient quantities.

Qualifications for adjustment tasks

Settings in the expanded menus of the control software require knowledge based on experience: – The adjustment personnel must be familiar

with how the labeller functions.

– Adjustment personnel must be familiar with

the entire system into which the labeller is integrated.

– Adjustment personnel must be able to cor-

rectly apply the functions in the expanded menu system to appropriately address the order-specific requirements.

Page 10

1PLEASE OBSERVE THE FOLLOWING:

1.2 S

1.2.2 Machine operating safety

Appropriate use

AFETY INSTRUCTIONS

ALS

380

The ALS 380 labeller is a fully automatic machine for the application of self-adhesive labels to products or packages. The machine is to be equipped by the operation planners with suitable safety devices so as to protect the operating personnel from possible endangerment – e.g. pinching or entrapment of body parts due to reaching between product and dispensing edge.

WARNING!

Improper usage of the machine can lead to accidents, material damage and loss of production!

➔ Only operate this machine in accordance

with information contained in this manual.

➔ Do not put the machine into operation

without the required safety equipment in place.

➔ Only make adjustments to the machine in

accordance with this manual and with all due care.

Protect against injuries that can result from electrical current

WARNING!

The machine is connected with the mains supply! Contact with energised components can result in life-endangering currents through the body as well as burns.

➔ Only put the machine into operation when

installed in a correctly installed housing.

– The housing may only be removed by

trained personnel when the machine is de-energised.

➔ Pull out the mains power connection plug

from the socket before cleaning and maintenance.

The machine is not protected against splashing water.

➔ Maintain the machine in a dry condition. ➔ In case fluids penetrate into the machine

interior, immediately switch off the machine and disconnect or plug out from the mains power supply. Notify a servicing technician.

Protect against injuries that can result from mechanical actions

WARNING!

Risk of injury due to moving or rapidly rotating parts!

➔ The following regulations always apply:

➔ Keep a distance from running machines. Wear

snug-fitting clothing and hair nets.

➔ Even when the machine is idle, maintain the area

clear of movable parts if the possibility exists that the machine could start.

➔ Never lay tools or loose parts on the machine if the

possibility exists that the machine could start.

➔ Switch off the machine before performing mechani-

cal adjustment tasks.

➔ Do not wear ties, loose garments, jewellery, watch-

es or similar articles on the body when in the machine vicinity.

CAUTION!

Danger of body part trapping and pinching at the dispensing edge due to products moving in the conveyor direction!

➔ Never reach between the product and dis-

pensing edge of running or operationready machines.

➔ During operation, never remove or defeat

the purpose of protective guards that prevent reaching into the machine.

Protection against chemicals

CAUTION!

Operational materials such as cleaning agents or adhesive solvents may pose a health risk.

➔ Rules, work guidelines and safety regula-

tions issued by the manufacturer must absolutely be followed!

Page 11

1PLEASE OBSERVE THE FOLLOWING:

1.2 S

1.2.3 Before every production start

AFETY INSTRUCTIONS

ALS

380

Operator's obligation and service personal to exercise care

➔ Ensure the following prerequisites correspond to the

information of the operating manual: – The machine is correctly installed and appropriately

configured for the requirements. – All necessary safety equipment is installed. – The machine has successfully completed at least

one test run. – The machine is connected to the power supply.

➔ The required personal safety gear, e.g. hair nets,

must be provided. Make sure that the safety gear is

used in accordance with the regulations.

Operating personnels' obligation to exercise care

➔ Verify flawless functioning of the safety equipment. ➔ Check machine for visible damage. Any discovered

deficiency is to be reported immediately.

➔ Use personal safety gear in accordance with the

regulations, e. g. wear hair nets.

➔ Non-required materials and objects are to be re-

moved from the working area of the machine.

➔ Make sure that only persons authorised to work on

the machine are within the working area of the machine.

➔ Make sure that no one will be placed in a hazardous

situation as a result of the machine startup.

Page 12

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

2 EQUIPMENT DESCRIPTION

2.1 OVERVIEW

2.1.1 Structural elements

ALS

380

[2] Right-hand version of the ALS 380 Labeller

Page 13

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

A Unwind unit – The unwinding spindle holds the label roll. – The spreader mechanism (chucking wedge) se-

cures the label roll.

B Dancer arm of the unwind unit – spring-loaded and rotatable

C Guiding rod for unwind unit – Also secures the label roll.

D Drive roller unit of the unwind unit

E Pressure roller of the unwind unit

F Braking brush up – Allows label ribbon to run smoothly, prevents flutter-

ing.

GCasing – Houses the control electronics, drive electrical sys-

tem, main switch, and fuses.

H Mounting brackets – For securing the machine in the system.

I Operator panel

J Braking brush down

K Dispenser head – With integrated label feed – Optionally equipped with printer or applicator

L Dispensing edge – The label separates from the backing material here.

M Rewind unit – An electrically driven rewinding roller takes up the

empty backing material. – A spreader mechanism secures the backing materi-

al roll.

2.1.2 Principle of operation

In labelling mode, the unwind unit [2A] and the drive roller unit move the [2D] label ribbon. A loop is formed in the label ribbon between the pressure roller of the unwind unit [2E] and the upper braking brush [2F]. An additional drive roller unit in the dispenser head [2K] pulls the ribbon over the dispensing edge [2L]. The label separates from the backing material at the dispensing edge.

The drive roller unit in the dispensing head moves the respective ribbon for a label and then stops until the next product takes the label under the dispensing edge. Label ribbon is continuously unwound at the unwind unit. The loop acts as a buffer between the continuously operating unwind unit and the periodically operating label output. The braking brushes keep the label ribbon taut.

From the dispensing head, the empty backing material runs over several deflection rollers [2 O] to the motor-driven spreaderrewinding unit [2M]. The multiple deflections with the spring-loaded dancer arm [2N] act as a buffer between the label output and the rewind unit.

The entire operation of the labeller is electronically controlled and monitored. If a malfunction occurs, the control system sends a corresponding message to the operator. If necessary, the labelling operation is automatically halted. An electronic signal is issued at the same time. The signal can be picked up by an external control system.

N Dancer arm of the rewind unit – spring-loaded and rotatable

O Deflection rollers of the rewind unit

Page 14

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

2.1.3 Technical data

ALS

380

Characteristic values

Dispensing speed ALS 380:

ALS 380 HS:

Stop accuracy (at the dispensing edge): ± 0.5 mm

Rewind unit: Spreader mechanism

Label sensor: Manual or automatic set-

Operation: programmable, can be set

Speed control: Automatic dispensing

0.5 m/min to 80 m/min

0.5 m/min to 100 m/min

ting

via the operator panel, The settings can be stored in 11 data banks

speed, with RPMtransmitter

Labels

Label width (incl. backing material): max. 155 mm

Label length at maximum dispensing speed:

Label roll

Outer diameter Core diameter:

Distance from dispensing edge to label sensor:

1) Longer labels are possible when product distance is increased accordingly

min. 16 mm max. 250 mm

max. 400 mm

76.2 mm

min. 20 mm

Ambient conditions

Temperature

Operation: Storage:

Relative humidity: 30 % to 80 %,

5°C to 40°C 5°C to 70°C

not condensing

Dimensions

Width: Height: Depth:

Weight ALS 380:

ALS 380 HS:

735 mm 795 mm 400 mm

50 kg 55 kg

Casing

Covering for the controlelectronics:

Front plate: Aluminium, anodized,

Polyurethane (PUR), 10 mm thick

15 mm thick

Electrical system

Power consumption: 500 VA

Mains connection

Nominal voltage:

Frequency:

Type of protection IP41 (protected against

Drive system: 2 stepping motors,

1) Customer options

110 V / 120 V / 130 V / 200 V / 220 V / 230 V/

240 V 50 Hz / 60 Hz

vertically falling drops of water, not protected against sprayed water)

1 AC motor

Control system

Control electronics: Integrated

Options: V24 interface

Frequency inverter for motor control

Emissions

Sound pressure level at a distance of 1 m: 75 db (A)

Page 15

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

2.1.4 Design versions

The ALS 380 labeller is available in 4 different versions, depending on the taskat hand:

Top-labeller right-hand version

ALS

380

– Labelling from above onto the upper side of the

product [3]. – The products are conveyed from left to right. – The dispensing edge is located on the right side.

Side-labeller right-hand version

– Labelling from the side onto one of the product’s

sides [4]. – The products are conveyed from left to right. – The dispensing edge is located on the right side.

B C

[3] Top-labeller right-hand version

A ALS 380 labeller B Product on conveyor line C Labelled product

AB C

[4] Side-labeller right-hand version

A ALS 380 labeller B Product on conveyor line C Labelled product

Page 16

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

Top-labeller left-hand version

– Labelling from above onto the upper side of the

product [5]. – The products are conveyed from right to left. – The dispensing edge is located on the left side.

Side-labeller left-hand version

– Labelling from the side onto one of the product’s

sides [6]. – The products are conveyed from right to left. – The dispensing edge is located on the left side.

Labeller operation is described in these instructions based on the top-labeller right-hand design version. Other design versions are only considered if their descriptions or illustrations differ.

ALS

380

[5] Top-labeller left-hand version

[6] Side-labeller left-hand version

Page 17

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

2.1.5 Options

ALS

380

High-speed processing version ALS 380 HS

– Allows dispensing speeds up to 100 m/min – Available in all of the above-mentioned design ver-

sions.

Serial interface

– Almost all of the setting values can be read out and

modified on an external device, the machine status

can be queried, and the machine can be controlled

via this interface.

Roll diameter control

– A sensor at the unwind unit monitors the diameter of

the label roll and, along with it, the supply of labels. – The sensor sends a signal when the diameter of the

label roll reaches a set value. – This sensor is required if two labellers are operating

in tandem mode (see chapter Operation - Activation

and shut-down, Tandem operation)

Printer

– Inkjet or heat transfer printer at the dispenser head.

Applicator

If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator. Various kinds of applicators are available depending on the customer’s needs.

Adjustable dispensing edge

– The position of the dispenser head can be adjusted

vertically. – This allows adapting the position of the dispensing

edge to changing products. – The machine does not have to be moved to adjust

the dispensing edge. The labelling head of the ma-

chine does not have to be released.

Page 18

2EQUIPMENT DESCRIPTION

2.2 OPERATOR CONTROLS

2.2.1 Operator panel

ALS

380

LED indicator

– Display of functions, setting values, operating

states, error messages, and warning messages

If the LED indicator is ON: – The machine is in labelling mode. – Each time the product sensor is triggered, a label is

dispensed. If the LED indicator is OFF: – Labelling mode is switched off.

Keys

FEED

– When this key is pressed, the machine dispenses a

label.

PRIOR (previous function)

– Paging through the functions in the menu: to see the

previous function, page upward. – Within a function: increase the current value

NEXT (next function)

– Paging through the functions in the menu: to see the

next function, page downward. – Within a function: decrease current value

[7] Operator panel for the ALS 380

A LED indicator B FEED key C PRIOR key D NEXT key E ENTER key

ENTER

– Activate or switch off labelling mode. – Call up or end functions. – Acknowledge error and warning messages.

Depending on the menu and the operating state of the machine, special key functions are also available. Where special functions are available, they are described in the relevant chapter.

Page 19

2EQUIPMENT DESCRIPTION

2.2 OPERATOR CONTROLS

2.2.2 Main switch

– The main switch [8] is located to the left on the

housing. – The main switch is used to switch the machine on

and off.

ALS

380

WARNING!

Contact with energised components can result in life-endangering currents through the body as well as burns. Voltage continues to be present in the housing even when switched off.

➔ Only put the machine into operation when

installed in a correctly installed housing.

➔ Maintain the machine in a dry condition.

[8] Main switch on the housing

Page 20

2EQUIPMENT DESCRIPTION

2.3 CONTROL SYSTEM

2.3.1 Brief description

ALS

380

All of the machine’s functions are electronically controlled. Using the operator panel, the operators, calibration technicians, or service personnel have several options for adapting the machine's functions to current requirements.

The LED indicator gives the operator feedback messages regarding the current operating state of the machine. Error messages or warning messages appear on the display as necessary.

Before each operation, the operator must check and adjust the occasionally changing settings such as the label position on the product or the dispensing speed. These settings can simply be input at any time by the operator at the operator panel.

Task-specific data such as label distance or product length are programmed at the beginning of a job. As a rule, the settings are not modified as long as the job is being processed. This data input requires in-depth knowledge and may only be carried out by trained and instructed personnel (calibration technicians).

Databanks are available for variable or frequently recurring task settings. The task-specific settings can be saved in a databank. If the settings are needed again after a product change, it is not necessary to re-input the data. You only need to call up the corresponding databank. In all, 11 databanks are available. Only calibration technicians may administer the product databanks.

It is also possible to modify the basic machine settings. These are settings such as the motor’s direction of rotation. These settings are not to be changed in normal operation. They may only be changed by servicing personnel or the responsible servicing technician.

To give the operator a better overview, the setting options for occasionally changing settings, task-specific data, databanks, and basic settings are grouped together in menus: The standard menu, extended menu, product databanks, and configuration menu. The following table provides an overview of the range of functions of the standard menu, extended menu, and product databanks. The configuration menu is described in the service guide.

CAUTION!

Erroneous settings can lead to production setbacks, damage to the machine and system, and can even cause work-related accidents! – Only specially trained and instructed per-

sonnel may alter the settings in the extended menu or access the product databanks.

Page 21

2EQUIPMENT DESCRIPTION

2.3 CONTROL SYSTEM

2.3.2 Menus for operators and calibration technicians

Menu Standard menu Extended menu Product databanks

Functions ON ON ON

OFF OFF OFF

INIT INIT PD01

VELO VELO PD02

STOD STOD PD03

POS POS PD04

POS 2 PD05

POS 3 PD06

VERT PD07

CONT PD08

E–SS PD09

ALS

380

LPIT PD10

PRDL PD11

P_S_

S_S_

MLAB

PDT

PDWT

EGRA

TMOD

APPL

APT1

APT2

APT3

APT4

LOAD

SAVE

DEL

QUIT

Activating a menu

Not ALS 380HS

Main switch + NEXT PRIOR + NEXT Main switch +

PRIOR

Page 22

2EQUIPMENT DESCRIPTION

2.3 CONTROL SYSTEM

2.3.3 Monitoring functions

During labelling operation, the electronic control system and the sensors monitor the following functions.

Dispensing a label to each product

– A photoelectric sensor (product sensor) sends a sig-

nal when a product reaches the dispensing

edge [9B]. The signal from the product sensor trig-

gers the label feed for a single label. – If individual labels are missing from the label ribbon,

the label feed compensates for this and advances

the label ribbon by one additional label distance (la-

bel compensation). – If label compensation does not take place before the

next start signal of the product sensor, the product

does not get labelled. A warning message appears

at the operator panel. – If the number of unlabelled products exceeds a cer-

tain value, the machine stops.

ALS

380

Label supply

– If no more labels arrive at the label stop sensor [9A]

[10A], the machine stops and sends a signal to the

output to the system controller. – Install roll diameter control (optional):

If the diameter of the label roll on the unwinding

spool [9C] becomes too small, the control system

sends a warning message and a signal to the output

to the system controller. The diameter at which the

signal will be sent can be set by servicing techni-

cians.

If errors occur

If a malfunction occurs, the control system sends a corresponding message to the operator. If necessary, the labelling operation is automatically halted. The machine simultaneously sends a signal to the system controller.

[9] A Label stop sensor

B The product sensor sends a signal when the product has

reached the dispensing edge.

C Label roll on the unwinding spool

[10] Backing material with a label under the label stop sensor (A)

Page 23

3PRIOR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

3 PRI OR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

3.1.1 Prerequisites

– The label dispenser is switched off at the main

[11A] switch.

ALS

380

➔ Verify flawless functioning of the safety equipment. ➔ Check machine for visible damage. Any discovered

deficiency is to be reported immediately.

➔ Non-required materials and objects are to be re-

moved from the working area of the machine.

➔ Make sure that only persons authorised to work on

the machine are within the working area of the ma-

chine.

➔ Use required personal safety gear in accordance

with the regulations, e.g. wear hair nets, and protec-

tive eye-glasses.

3.1.2 Insert the label roller

WARNING!

Risk of injury due to moving or rapidly rotating parts!

➔ Before inserting the label roller, ensure

that the machine is switched off at the main switch.

➔ Never switch on the machine before the

label ribbon has been completely threaded into position.

[11] Main switch on the housing

Remove the old backing material

If backing material remains on the rewinding [12A] roller:

➔ Swing the lever [12C] at the rewinding roller over the

red [12B] point. – The tension of the rewinding roller spreader mecha-

nism is relieved.

➔ Remove the rewound backing material.

Remove adhesive residues

➔ If necessary, clean the following components:

– Dispensing edge – Deflection rollers and drive roller unit in the dispens-

er head – Dancer arm rollers and deflection rollers – Rewinding roller

[12] Remove the backing material from the rewinding roller

A Old backing material B Red point on the rewinding roller C Lever for the spreader mechanism of the rewinding roller

Page 24

3PRIOR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

Insert new label roll

Only top-labeller:

➔ Loosen the set-screw at the guiding rod [13C] and

swing the guiding rod to the side.

ALS

380

All design versions:

➔ Rotate the knurled knob [13B] clockwise, to retract

the chucking wedge [13A] in the unwinding spindle.

➔ If there is still an old roll core on the unwinding spin-

dle: remove the old roll core.

➔ Completely push on the new label roll. ➔ Rotate the knurled knob counter-clockwise to se-

cure the label roll on the unwinding spindle.

Also for top-labeller: Also secure the label roll to the dancer arm in the axial direction:

➔ Allow the dancer arm to lightly rest against the label

roll and

➔ swing it approximately 1 cm over the unwinding

spindle. The dancer arm must not be allowed to

touch the unwinding spindle.

➔ Tighten the set-screw at the guiding rod.

[13] New label roll on the unwinding spindle, secured to the guiding

rod on the side

A Chucking wedge in the unwinding spindle B Knurled knob on the unwinding spindle C Guiding rod

Page 25

3PRIOR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

3.1.3 Threading the label ribbon

Overview of the threading path diagram

ALS

380

A B

[14] Threading path diagram for label ribbon with the labels on the outside

A Right-hand version B Left-hand version

A B

[15] Threading path diagram for label ribbon with the labels on the inside

A Right-hand version B Left-hand version

Page 26

3PRIOR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

ALS

380

Thread the label ribbon at the unwind unit.

➔ Swing up the pressure roller [16B] and the braking

brush [16C].

➔ Thread the label ribbon around the deflection

roller [16E], dancer armroller [16A] and drive roller

unit [16D].

➔ Form a loop after the drive roller unit and guide the

label ribbon over the operator panel support [16F].

➔ Swing the pressure roller and web brake back into

position. – The pressure roller and braking brush click into op-

erating position.

B C

[16] Guides for the label ribbon in the unwinding section

A Dancer arm roller B Pressure roller C Braking brush D Drive roller unit E Deflection roller F Operator panel support

Page 27

3PRIOR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

Thread in the label ribbon at the dispensing edge.

➔ Swing up the pressure roller [17D] behind the dis-

pensing edge.

➔ Unthread approximately 2 m of label ribbon from the

label roll.

➔ Guide the label ribbon around the first deflection

roller [17A] and through the slot in the photoelectric

sensor [17B] for the dispensing edge.

➔ Guide the label ribbon around the dispensing edge

to the drive roller unit [17C].

➔ Thread the label ribbon around the drive roller unit

and the second deflection roller [17E].

➔ Swing the pressure roller back into operating posi-

tion.

ALS

380

[17] Guides for the label ribbon at the dispensing edge

A 1st Deflection roller B Label stop sensor C Drive roller unit D Pressure roller (shown here in operating position) E 2nd Deflection roller

Page 28

3PRIOR TO OPERATING

3.1 INSERT THE LABELLING MATERIAL

Thread the label ribbon at the rewind unit.

➔ Thread the label ribbon around the deflection

rollers and the dancer armrollers as shown in

figure [18].

➔ Open the spreader mechanism of the rewinding roll-

er using the lever [18C]. – When the spreader mechanism is open, the red

point on the rewinding roller is visible.

➔ Insert the end of the label ribbon into the slot on the

rewinding roller.

➔ Rotate the rewinding roller counter-clockwise until

the label ribbon is under tension.

After a label roll is passed through, the backing material roll rests firmly on the rewinding roller. The spreader mechanism allows the diameter of the rewinding roller to be decreased. The backing material roll can then be easily removed.

➔ Only put the label ribbon on the rewinding

roller when the spreader mechanism is open (red point visible).

➔ Do not close the spreader mechanism before

the backing material is removed from the rewinding roller

ALS

380

[18] Guides for the label ribbon in the dancer arm rewinding section

A Deflection rollers B Dancer arm roller C Lever for the spreader mechanism of the rewinding roller (in

the open position)

Page 29

3PRIOR TO OPERATING

3.2 MECHANICAL SETTINGS

WARNING!

Risk of injury due to moving or rapidly rotating parts!

➔ Before carrying out the mechanical set-

tings, ensure that the machine is switched off at the main switch.

ALS

380

3.2.1 Setting the ribbon guides

Operator panel support

➔ Loosen the knurled thumb screws on the guide

rings [19A].

➔ Setting the ribbon guides

– Distance between label ribbon and front plate of

housing: 31.5 mm – The label ribbon must run between the guides with

as little play as possible, but it must not be pinched.

➔ Tighten the knurled thumb screws on the guide

rings.

Deflection rollers on the rewind unit

➔ Slide the guide bushes onto the deflection

rollers [19B]: – The label ribbon must not run from the side behind

the dispenser head.

[19] Ribbon guides

Page 30

3PRIOR TO OPERATING

3.2 MECHANICAL SETTINGS

3.2.2 Adjusting the braking brushes

Mounting locations of the braking brushes: – In front of the operator panel support [20A] – On the vertical guide for the dispensing edge [20B]

➔ Loosen the stud bolt [20C]. ➔ Align the braking brush centrally on the label ribbon. ➔ Tighten stud bolts.

ALS

380

[20] Braking brushes

Page 31

3PRIOR TO OPERATING

3.2 MECHANICAL SETTINGS

ALS

380

3.2.3 Adjusting the pressure rollers

Mounting locations of the pressure rollers: – On the drive roller unit of the unwind unit – On the drive roller unit of the label feed

➔ Loosen the knurled thumb screws on the setting

rings [21A].

➔ Raise the pressure roller slightly and centrally align

it on the label ribbon.

➔ Secure the pressure roller axially with the setting

rings. Tighten the knurled thumb screws.

[21] Pressure roller, centrally aligned on the label ribbon

Page 32

3PRIOR TO OPERATING

3.2 MECHANICAL SETTINGS

3.2.4 Adjust the pressure roller unit

(optional) at the dispensing edge.

Depending on the area of application, the labeller can be equipped with an additional pressure roller unit [22A] at the dispensing edge.

ALS

380

The most favourable positioning of the pressure roller unit differs depending on the application. For information on adjusting the pressure roller unit, the responsible servicing technician is at your disposal.

To set the position of the pressure roller unit relative to the label ribbon:

➔ Loosen the fastening screws [22B]. ➔ Adjust the pressure roller ➔ Tighten the fastening screws.

[22] Optional pressure roller unit

Page 33

3PRIOR TO OPERATING

3.2 MECHANICAL SETTINGS

3.2.5 Adjust (optional) the position

of the dispensing edge.

Adjusting vertically

Coarse adjustment:

➔ Open the central lock [23B]. ➔ Hold the dispenser head firmly and open the lower

lock [23C].

➔ Slide the dispenser head to the desired height and

tighten the lock [23C].

ALS

380

Fine adjustment:

➔ Open the upper lock [23A]. ➔ Rotate the spindle [23D] clockwise to move the dis-

pensing edge downward or rotate the spindle coun-

ter-clockwise to move the dispensing edge upward.

➔ Tighten the lock [23A] ➔ Tighten the central lock [23B].

For recurring adjustments when products are changed:

➔ Use the scales on the guide columns.

[23] Adjustable dispensing edge (optional)

Page 34

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

4 OPERATION

4.1 ACTIVATION AND SHUT-DOWN

4.1.1 Starting the machine

Before each use, the control system must be adapted to the inserted label material. During this, the label distance is detected and the photoelectric sensor at the dispenser head is adapted to the transparency of the labels and of the backing material. This process is called material initialisation.

ALS

380

Automatic material initialisation

Initialising material at switch-on:

➔ Press and hold the FEED key [24] and switch on the

machine at the main switch [25A]. – The message AUTO appears on the operator panel. – The machine slowly starts up and dispenses a label. – The label distance is automatically measured. – The photoelectric sensor is automatically adapted.

➔ Release the FEED key once a label gap has passed

the photoelectric sensor at the dispenser head.

If the initialisation was successful: – "ON" appears on the operator panel. – When the FEED key is pressed, a label is dis-

pensed.

If the initialisation was unsuccessful: – The message FAIL appears on the operator panel.

➔ Switch off and automatically re-initialise the ma-

chine.

or:

➔ Manually initialise the material employing

qualified calibration technicians.

[24] FEED key

[25] Main switch on the housing

Page 35

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

The machine can also be automatically initialised after switch-on by using the INIT function:

➔ In the standard menu, press the NEXT or PRIOR

key until INIT [26] is displayed on the operator pan-

el.

➔ Call the INIT function by pressing the ENTER key. ➔ Press and hold the FEED key.

– The message AUTO appears on the operator panel. – The machine slowly starts up and dispenses a label.

➔ Release the FEED key once a label gap has passed

the photoelectric sensor at the dispenser head.

– If the initialisation was successful, "ON" appears on

the operator panel.

ALS

380

[26] INIT display on the operator panel

Manually initialise the material

If automatic initialisation is not possible, it does not generally mean there is a malfunction. Manual initialisation is often required if:

– the proper label stop sensor is not installed. – transparent labels are used. – labels with only a slight difference of trans-

parency between label and backing material are used.

– perforated or otherwise blocked out labels

are used [27].

Only by qualified calibration technicians:

➔ Calling up the extended menu.

➔ Input the label distance using the LPIT

function

➔ Adjust the photoelectric sensor using the

CONT function.

➔ Refer to chapter Operation - Settings in the

extended menu.

BC C

[27] A Label distance

B Photoelectric sensor C Labels with block outs (perforations)

Page 36

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

4.1.2 Labelling

Prerequisites

– Label material is inserted. – Machine is switched on. – Material is initialised.

If "OFF" appears on the operator panel:

➔ Press the ENTER [28] key until ON [29A] is shown.

ALS

380

If "ON" appears on the operator panel [29A]: – The unwinding drive runs for a moment and fills the

loop space with label ribbon [29B].

– The dancer arm rewinding unit [29C] points down-

ward: The unwinding drive runs for a moment until the dancer arm points upward at an angle of approx. 45°.

– The machine is now ready for operation.

If no “ON” display appears on the operator pan-

el:

– The machine is possibly in offline mode or

one of the prerequisites for operation has not been met.

➔ Instruct a qualified and authorised servicing

technician to carry out the settings in the configuration menu.

– For further information, refer to the service

guide.

[28] ENTER key

[29] Operation-ready labeller

Page 37

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

Start dispensing labels

– The conveyor belt starts up. The first product reach-

es the product sensor (photoelectric sensor) [30]. – The product sensor sends a start signal. – The start signal from the product sensor triggers the

dispensing of a label (label feed) using the set val-

ues for dispensing speed, label distance, etc.

– The dispensing of labels automatically runs in the

same manner for the following products.

ALS

380

[30] The product sensor (A) has detected a product (B) at the dis-

pensing edge and sends a start signal

Page 38

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

Unwind unit

ALS

380

– A loop forms in the loop space as a buffer between

the unwind unit and label dispensing [31arrow]. – A photoelectric sensor in the loop space monitors

the loop. – If the loop becomes too large, the control system au-

tomatically lowers the unwinding speed. The dis-

pensing speed does not change. – The dancer arm [31A] swings approximately into the

centre position.

Rewind unit

– The multiple deflections with the spring-loaded

dancer arm act as a buffer between the label output

and the rewind unit. During synchronous operation,

the dancer arm is approximately in the centre

position [31B]. – If necessary, the control system automatically slows

the rewinding speed. The dispensing speed is not

affected by this.

4.1.3 Stop/end the label dispensing

➔ Press the ENTER key.

– The unwind unit, dispenser drive, and rewinding unit

shut down. – “OFF” appears on the operator panel [32].

[31] ALS 380 in labelling mode

[32] OFF display on the operator panel

Page 39

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

4.1.4 Tandem operation

A B

ALS

380

[33] Two labellers in tandem arrangement

A The active labeller, label roll comes to its end B Labeller in standby with full label roll, “LOCK” appears on the operator panel

Principle of operation

In tandem operation, two labellers are arranged one behind the other. Only one of the labellers is in operation at a time. The other remains in standby. If the active labeller reports the end of the label roll, it shuts down. The other labeller takes over the task of labelling. The shut-down labeller can now be loaded with label material.

The LED indicators on the operator panels of the two machines indicate their respective operating states. – ON on the operator panel of the currently active ma-

chine – LOCK on the operator panel of the machine in

standby – W__5, if the respective machine has shut down due

to reaching the end of the label roll

During automatic switch-over from one machine to the other, the distance between the two machines and their arrangement are taken into consideration. As a rule, unlabelled products can be prevented. This guarantees uninterrupted labelling operation. Reloading periods do not affect the course of production.

The first machine in the production line is designated as the master device, the second is designated as the slave device.

In tandem operation, the dispensing speed is automatically adapted to the speed of the conveyor belt (also see chapter Automatic dispensing speed adjustment).

Page 40

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

Prerequisites

ALS

380

– Both machines are configured and tested for tan-

dem operation and automatic dispensing speed ad-

justment. – Label material is inserted, machines are switched

on, material is initialised. – "OFF" appears on the operator panels of both ma-

chines.

On the machine that is to begin labelling first:

➔ Press the ENTER key [34B].

– The operator panel of this machine indicates

ON [34A]. This machine is activated.

On the other machine:

➔ Press the ENTER key.

– The operator panel of this machine indicates LOCK.

Start dispensing labels

– The conveyor belt starts up. The first product reach-

es the product sensor [35A] of the activated ma-

chine. – The product sensor sends a start signal. – The machine with the ON indication starts

dispensing [35labels B]. – The machine with the LOCK indication remains in

standby [35C].

[34] Operator panel for the ALS 380

A “ON" LED indicator B ENTER key

B C

[35] Start of the label dispensing in tandem operation

A The first product has reached the product sensor of the ma-

chine that is to begin labelling first.

B The machine with the ON indication starts dispensing labels. C The machine with the LOCK indication remains in standby.

Page 41

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

Reloading label material

WARNING!

Risk of injury from the running conveyor line at the workplace! Risk of pinching at the dispensing edge!

➔ Before reloading label material, ensure

that the machine in question does not start up unintentionally. The operator panel must indicate the W__5 warning message.

➔ Absolutely avoid coming into contact

with the conveyor line and the moving products.

➔ Only join the old and new label ribbons

together in the unwinding section or in the loop space. Never contact objects in the space near the dispensing edge.

➔ If it is not possible to reload label material

safely: Stop operation (see next page).

ALS

380

On the active machine, the label material runs low [36]: – The machine stops, even before the end of the label

material reaches the dispensing edge. – The machine's display changes to W__5. – The other machine is automatically activated. – The display of the currently active machine indicates

ON.

On the idle machine (display W__5):

➔ Remove the old roll core from the unwinding spool.

Leave the remainder of the label ribbon on the ma-

chine.

➔ Insert new label roll. ➔ Join the beginning of the label ribbon of the new la-

bel roll to the end of the old label ribbon with adhe-

sive.

➔ Press the ENTER key. ➔ The indication changes to LOCK. The machine is

now in standby

For procedure for changing the label roll, see section Prior to operating, chapter Insert the la- belling material – Insert the label roller.

A B

[36] Prerequisites for reloading label material during operation:

A The label roll is empty on the first machine. The machine is

not running. The end of the label material is still in the loop space. The operator panel indicates W__5.

B The second machine automatically takes over the labelling.

The operator panel indicates ON.

Page 42

4OPERATION

4.1 ACTIVATION AND SHUT-DOWN

Switching off

Switch over the active machine

On the operator panel of the active machine:

➔ Press the FEED [37] key.

– The indication on the operator panel changes from

ON to BUSY, until the machine stops. – The machine switches over to standby. The opera-

tor panel indicates LOCK.

ALS

380

– The other machine is activated.

Stopping operation

On the operator panel of the active machine:

➔ Press the ENTER key.

– The machine stops, the operator panel indicates

OFF. – The other machine is activated.

On the operator panel of the now active machine: – The indication on the operator panel changes from

LOCK to ON.

➔ Press the ENTER key.

– The machine stops, the operator panel indicates

OFF.

To resume operation:

➔ On the machine that is to begin labelling first: press

the ENTER key. – The operator panel of this machine indicates ON.

➔ On the other machine: press the ENTER key.

– The operator panel of this machine indicates LOCK. – As soon as the product sensor sends a start signal,

the labelling operaton is activated.

[37] FEED key

If the currently active machine is switched off at the main switch, while the second machine is in standby: – The second machine is automatically activat-

ed.

➔ Do not interrupt tandem operation using the

main switches.

➔ Only actuate the main switch if the operator

panels of the two machines indicate OFF.

Page 43

4OPERATION

4.2 SETTING AND MONITORING

4.2.1 Settings in the standard menu

Overview

ALS

380

Function/ Display

ON Activate labelling mode

OFF End labelling mode

INIT Automatic material initialisation

VELO Dispensing speed

STOD Distance between dispensing edge and leading edge of the label

POS Distance between leading edge of product and label

[38] Functions in the standard menu

Brief description

Calling up menu

– The standard menu is automatically started when

the machine is switched on, if it was active before

the last shut-down of the machine. – If the standard menu does not automatically acti-

vate: The machine will switch off and back on when

the NEXT [39B] key is pressed.

Call up function

– The desired function can be selected by pressing

the NEXT [39B] and PRIOR [39A] keys. – The function is called up by pressing the

ENTER [39C] key. – To exit the function, press the ENTER key again.

[39] Operator panel in the standard menu

Page 44

4OPERATION

4.2 SETTING AND MONITORING

4.2.2 Label stop position

(STOD)

After the label is output, the feed continues to operate, until the next label is present at the dispensing edge. To ensure that the labels separate completely from the dispensing edge, it is advisable to allow the feed to run until the next label projects slightly over the dispensing edge. The label stop position is the distance between the leading edge of the next label and the dispensing edge [40A]. As a rule, this distance should not be more than 3 mm. The respective optimum setting value depends on the label material used, the product speed, the surface characteristics of the product, and other factors.

➔ For problems during the labelling operation, first

check the label stop position.

➔ If necessary, set the label stop position as described

below.

ALS

380

➔ Switch on the machine at the main switch. ➔ In the standard menu, press the NEXT [41A] or

PRIOR [41B] key until STOD [42] is displayed on

the operator panel.

➔ Call up the STOD function by pressing the

ENTER [41C] key. – The distance is shown on the operator panel in mm.

➔ Set the desired distance using the NEXT or PRIOR

key. – Settings are possible in 0.1 mm steps:

Minimum: 0 mm

Maximum: set label distance (LPIT function)

➔ Confirm the setting using the ENTER key and exit

the STOD function.

If the value for the STOD function shown on the operator panel does not agree with the actual label stop position, it is possible that the control system contains an erroneous value for the distance between the photoelectric sensor and the dispensing edge (E_SS function in the extended menu).

[40] A Distance between dispensing edge and leading edge of the

label

A CB

[41] Symbols on the operator panel keys

A NEXT key B PRIOR key C ENTER key

[42] STOD display on the operator panel

Page 45

4OPERATION

4.2 SETTING AND MONITORING

4.2.3 Dispensing speed (VELO)

As a rule, the labelling speed must correspond to the product speed. Depending on the operating conditions, the labelling speed can also be set somewhat higher in unique cases.

Prerequisites: – The label stop position (STOD) is correctly set.

ALS

380

A CB

➔ In the standard menu, press the NEXT [43A] or

PRIOR [43B] key until VELO [44] is displayed on

the operator panel.

➔ Call up the VELO function by pressing the

ENTER [43C] key. – The current speed is displayed on the operator pan-

el in m/min.

➔ Change the labelling speed using the NEXT or PRI-

OR key. – Settings are permitted in steps of 0.1 m/min:

Minimum: 0.5 m/min

Maximum: 80 m/min (ALS 380 HS: to 100 m/min) – Confirm the setting using the ENTER key and exit

the VELO function.

Test the setting:

➔ Remove the pressure roller unit (optional) at the dis-

pensing edge.

➔ Start the system and only label one product.

– The labelling speed is too low if the product pulls the

label away from the backing material. – The labelling speed is too high if the label on the

product has folds in it.

[43] Symbols on the operator panel keys

A NEXT key B PRIOR key C ENTER key

[44] VELO display on the operator panel

Automatic dispensing speed (optional)

If the automatic dispensing speed (APSF) is activated: – Only display of the current speed using the VELO

function. – Manual setting of the dispensing speed is not possi-

ble. – For further information on the APSF function, see

chapter Operation - Automatic dispensing speed.

Page 46

4OPERATION

4.2 SETTING AND MONITORING

4.2.4 Label position on the product

(POS)

– Distance between leading edge of the product and

leading edge of the label [45A]

ALS

380

Prerequisites: – The label stop position (STOD) is correctly set. – The dispensing speed (VELO) is correctly set.

➔ In the standard menu, press the NEXT [46A] or

PRIOR [46B] key until POS [47] is displayed on the

operator panel.

➔ Call up the POS function by pressing the

ENTER [46C] key. – The distance is shown on the operator panel in mm.

➔ Set the desired distance using the NEXT or PRIOR

key. – Settings are possible in 0.1 mm steps:

Minimum: 10 mm

Maximum: 999.9 mm

➔ Confirm the setting using the ENTER key and exit

the POS function.

Note: POS actually sets the path that the product follows from the product sensor to the triggering of the labelling. If the product sensor is located at the level of the dispensing edge, this is the distance between the leading edge of the product and the label.

[45] A Value for the POS function

A CB

[46] Symbols on the operator panel keys

A NEXT key B PRIOR key C ENTER key

[47] POS display on the operator panel

Page 47

4OPERATION

4.2 SETTING AND MONITORING

4.2.5 Automatic material

initialisation (INIT)

Also refer to chapter Activation and shut-down.

➔ In the standard menu, press the NEXT or PRIOR

key until INIT [48] is displayed on the operator pan-

el.

➔ Call the INIT function by pressing the ENTER key. ➔ Press and hold the FEED key.

– The message AUTO appears on the operator panel. – The machine slowly starts up and dispenses a label.

➔ Release the FEED key once a label gap has passed

the photoelectric sensor [49A] at the dispenser

head.

ALS

380

[48] INIT display on the operator panel

If the initialisation was successful: – "ON" appears on the operator panel. – When the FEED key is pressed, a label is dis-

pensed.

If the initialisation was unsuccessful: – The message FAIL appears on the operator panel.

➔ Initiate the INIT function again.

or:

➔ Manually initialise the material employing

qualified calibration technicians.

If the FEED key is not pressed down when INIT is displayed on the operator panel, but only lightly actuated: – The values for the label distance setting and

the label stop sensor will be deleted provided these values are stored in the control unit.

– Continual feed at maximum speed is trig-

gered.

– The continual feed only stops after a mal-

function occurs.

➔ To prevent operational malfunctions, switch

off the machine at the main switch as soon as possible.

[49] Backing material with a label under the label stop sensor (A)

Page 48

4OPERATION

4.2 SETTING AND MONITORING

4.2.6 If errors occur

Warning messages

If the machine control system detects a malfunction, but the labelling operation does not have to be interrupted: – A warning message appears on the LED-indicator

of the operator panel. – A warning message is displayed in the format

W_nn:

W stands for warning,

nn is a two-digit numerical code. – An electronic signal is issued at the same time. The

signal can be further processed by an external con-

trol system. – For an explanation of the warning messages and

notes on fault elimination, see chapter Operational

malfunctions.

ALS

380

[50] Example: The warning message W__4 is displayed on the op-

erator panel

Example [50]: – The current labelling speed is too high. – The warning message W__4 appears on the opera-

tor panel. – An electronic signal is sent to the system control. – The system control issues an additional warning

tone.

Page 49

4OPERATION

4.2 SETTING AND MONITORING

Error messages

If the machine control system detects a serious malfunction: – The labelling operation is automatically halted. – An error message appears on the LED-indicator of

the operator panel. – A warning message is displayed in the format E_nn:

E stands for error,

nn is a two-digit numerical code. – An electronic signal is issued at the same time. The

signal can be further processed by an external con-

trol system. – For an explanation of the error messages and notes

on fault elimination, see chapter Operational mal-

functions.

Example [51]: – The label ribbon is torn. – The error message E__6 appears on the operator

panel. – An electronic signal is sent to the system control. – The system control issues an additonal warning

tone and stops the conveyor belt.

ALS

380

[51] Example: The error message E__6 is displayed on the operator

panel

Page 50

4OPERATION

4.3 PRODUCT DATABANKS

ALS

380

4.3.1 Functions

Task-specific settings that do not need to be modified for daily operation:

–POS –MLAB

–POS2 –PDT

–POS3 –PDWT

– VELO – EGRA

– STOD – VERT

– CONT – APPL

– E–SS – APT1

– LPIT – APT2

– PRDL – APT3

– P_S_ – APT4

–S_S_

4.3.2 Loading product data banks

Please observe:

CAUTION!

Erroneous settings can lead to production setbacks, damage to the machine and system, and can even cause work-related accidents! – Only qualified and specially trained per-

sonnel or the responsible servicing technician are authorised to access the product databanks.

Page 51

4OPERATION

4.3 PRODUCT DATABANKS

Activating product databanks at switch-on

–The menu Product databanks is only available if at

least one product databank is created.

➔ While switching on the machine, press and hold the

PRIOR key. – The product databank menu is activated. – The indicator with the last activated product

databank [52] blinks.

➔ Repeatedly press the NEXT or PRIOR key until the

desired product databank is shown on the display.

➔ Activate the product databank by pressing the

ENTER key. – Once the label dispensing is started, the settings of

the activated product databank are adopted.

ALS

380

[52] Example: Product databank PD01

The product databank menu is automatically started when the machine is switched on, if it was active before the last shut-down of the machine. If the machine is operated by personnel who are not authorised to work in the product databank menu :

➔ Switch off the machine at the main switch. ➔ Press and hold the NEXT key and switch the

machine on again at the main switch.

– The standard menu is activated.

Activating product databanks after switch-on

In the extended menu:

➔ Call up the LOAD function.

– The indicator with the last activated product data-

bank [53] blinks.

➔ Repeatedly press the NEXT or PRIOR key until the

desired product databank is shown on the display.

➔ Activate the desired product databank by pressing

the ENTER key. – Once the label dispensing is started, the settings of

the activated product databank are adopted.

[53] Example: Product databank PD01

➔ Exit the extended menu using QUIT.

Page 52

4OPERATION

4.3 PRODUCT DATABANKS

4.3.3 Create/save product databank

ALS

380

Prerequisites

CAUTION!

Erroneous settings can lead to production setbacks, damage to the machine and system! – Only appropriately qualified and author-

ised personnel may create product databanks.

– Settings in the following functions are updated:

–POS –MLAB

–POS2 –PDT

–POS3 –PDWT

– VELO – EGRA

– STOD – VERT

– CONT – APPL

– E–SS – APT1

– LPIT – APT2

– PRDL – APT3

– P_S_ – APT4

Saving the product databank

In the extended menu:

➔ Call up the SAVE function. ➔ Select the desired product databank using the

NEXT or PRIOR key.

– 11 product databanks are available.

➔ Using the ENTER key, save the current settings in

the selected product databank.

➔ Exit the extended menu using QUIT.

If the selected product databank already contains data:

– The question YES? appears on the display.

➔ Confirm the query by pressing the ENTER key to

overwrite the selected product databank with the new data.

Should the product databank not be overwritten:

➔ Press the NEXT key until QUIT appears on the dis-

play.

➔ Press the ENTER key.

– The selected product databank is closed without be-

ing saved.

➔ Select another product databank to save the current

settings.

–S_S_

1) Setting the EGRA is required when operating the automatic dispensing

speed adjustment APSF

Documenting product databanks

➔ Document the contents of the product databanks in

a table. Use the example copy in the appendix.

Page 53

4OPERATION

4.3 PRODUCT DATABANKS

4.3.4 Deleting a product databank

In the extended menu:

➔ Call up the DEL function. ➔ Select the desired product databank using the

NEXT or PRIOR key. – Only product databanks that contain data are

shown. – The indicator with the last activated product data-

bank blinks. This product databank cannot be delet-

ed.

➔ Delete the selected product databank by pressing

the ENTER key.

➔ Exit the extended menu using QUIT.

ALS

380

If the last activated product databank is deleted:

➔ Select another product databank using the LOAD

function. – The desired product databank can now be deleted

using the DEL function.

Page 54

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.1 Overview

ALS

380

Function/display

ON The machine is ready for operation / start dispensing labels

OFF Stop/end the label dispensing

INIT Automatic material initialisation

VELO Dispensing speed

STOD Distance between dispensing edge and leading edge of the label

POS Distance between leading edge of product (product sensor) and label

POS 2 Distance between the leading edges of the first and second label on the same product

POS 3 Distance between the leading edges of the second and third label on the same product

VERT Relationship between the dispensing speed and the conveyor belt speed

CONT Adjust the label stop sensor

E–SS Distance between label stop sensor and dispensing edge

LPIT Label distance

PRDL Product length

P_S_ Polarity of the product sensor

S_S_ Polarity of the label stop sensor

Brief description

MLAB Allowable number of unlabelled products

EGRA Compensation factor for RPM transmitter when operating with automatic dispensing speed

adjustment (not with ALS 380 HS, see Service Guide)

TMOD Activate and deactivate tandem operation

LOAD Loading product data banks

SAVE Create and save a product data bank

DEL Deleting a product databank

QUIT Exit the extended menu

[54] Functions in the extended menu of the ALS 380

Page 55

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

In addition, when using a printer (optional):

PDT Print delay

PDWT Printer dwell time

[55] Additional functions for printers

Additional functions when using an Applicator (optional):

APPL Set the applicator type used

APT1 Set the dwell time for the EP cylinder

APT2 Dwell time for blowing the label on the product

APT3 Idle time of the applicator between two labelling processes

APT4 Fine tuning of the applicator dwell time in connection with APSF

ALS

380

[56] Additional functions for the applicator

Page 56

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.2 Activating an extended menu

Please observe:

CAUTION!

Erroneous settings can lead to production setbacks, damage to the machine and system, and can even cause work-related accidents! – Only specially trained and instructed per-

sonnel may alter the settings in the extended menu.

Calling up menu

– To access the extended menu, you must enter a

password.

➔ Simultaneously press the NEXT and PRIOR keys.

– CODE appears on the LED display.

➔ Enter the password [57].

– The following appears on the LED display for ap-

prox. 1 second: – The extended menu is active.

****

[57] Key sequence (password) for the extended menu

ALS

380

Call up function

➔ Repeatedly press the NEXT or PRIOR key until the

desired function is shown on the display.

➔ Call up the function using the ENTER key.

➔ To exit the function, press the ENTER key again.

Exit the extended menu

➔ Press the NEXT or PRIOR key until QUIT appears

on the display.

➔ Press the ENTER key.

– This exits the extended menu. – The last active menu is active again.

If the machine is now to be operated by personnel who are not authorised to work in the extended menu:

➔ Ensure that the standard menu is active.

Page 57

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.3 Position of second label

(POS2)

If the products are to be given two labels: – Distance between the leading edges of the first and

second label [58A].

ALS

380

In the extended menu:

➔ Call up the POS2 function. ➔ Set the desired distance.

– Settings are possible in 0.1 mm steps: minimum la-

bel length,

maximum 999.9 mm – POS2 is not active if the value is set to 0.

➔ Confirm the setting using the ENTER key and exit

the POS2 function.

4.4.4 Position of third label (POS3)

If the products are to be given three labels: – Distance between the leading edges of the second

and third label [59A].

In the extended menu:

➔ Call up the POS3 function. ➔ Set the desired distance.

– Settings are possible in 0.1 mm steps: minimum la-

bel length,

maximum 999.9 mm – POS3 is not active if the value is set to 0.

➔ Confirm the setting using the ENTER key and exit

the POS3 function.

[58] A Position of second label: Distance between the leading edges

of the first and second label

[59] A Position of third label: Distance between the leading edges of

the second and third label

Page 58

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.5 Speed ratio (VERT)

– Relationship between the dispensing speed and the

conveyor belt speed

Example [60]: Circumferential labelling of a round product. The product simultaneously makes a linear movement and a rotational movement.

In the extended menu:

➔ Call up the VERT function.

– The preset is 100 (corresponds to a ratio of 1:1)

➔ Set the desired value.

– Possible settings: 80 to 1000 (corresponds to 0.8:1

to 10:1)

➔ Confirm the value using the ENTER key and exit

the VERT function.

ALS

380

Example [60]: – The rotational speed [A] is twice as great as the lin-

ear speed of the product [B]. – The dispensing speed must roughly correspond to

the rotational speed.

➔ Set the setting for VERT to 200 (ratio 2:1).

➔ If necessary, use the fine adjustment.

[60] Example: The product simultaneously moves from left to right

and rotates about its axis

A Rotational speed B Linear speed (conveyor belt speed)

Page 59

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.6 Adjust the label stop sensor (CONT)

ALS

380

Technology

Automatic and manual adjustment

The sensitivity of the label stop sensor must be adjusted to match the transparency of the labels and the backing material. In most applications, it is possible to allow the sensitivity of the sensor to be adjusted automatically.

When using labels with only a slight difference in the transparency of the label and the backing material, perforated labels or labels with block outs:

➔ Manually adjust the sensors as described below.

Non-standard photoelectric sensors

In series production, the labeller is equipped with a photoelectric sensor manufactured by Wenglor.

When using transparent labels or labels with a very slight difference in the transparency of the label and the backing material: – It is possible that the gap between two labels will not

be detected. Instead of just one label, two or more

labels might be dispensed. – Use of a mechanical or capacitive sensor is recom-

mended. – A mechanical sensor is only of limited use at high

dispensing speeds.

Automatically adjusting the photoelectric sensor

➔ Press and hold the FEED key and switch on the ma-

chine at the main switch.

– The message AUTO appears on the operator panel.

or:

➔ When the machine is switched on, call up the INIT

function.

➔ Press and hold the FEED key.

– The machine slowly starts up and dispenses a label. – The label distance is automatically measured. – The photoelectric sensor is adjusted.

➔ Release the FEED key once a label gap has passed

the photoelectric sensor at the dispenser head.

If the adjustment (measurement) was successful: – "ON" appears on the operator panel.

If the adjustment (measurement) was not successful: – The message FAIL appears on the operator panel.

➔ Manually adjust the sensor.

When using a non-series production photoelectric sensor:

➔ Reduce the setting value for CONT to NONE.

– For information on connecting a mechanical or ca-

pacitive sensor, see the Service Guide.

Page 60

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

Manually adjusting the sensor.

In the extended menu:

➔ Call up the CONT function.

➔ Insert the backing material without a label under the

photoelectric sensor.

➔ Press the PRIOR key until the yellow LED on the

photoelectric sensor [61A] illuminates.

➔ Press the NEXT key in stages until the yellow LED

extinguishes again.

➔ Make note of the value displayed when the LED ex-

tinguishes: Value of the backing material.

ALS

380

➔ Insert the backing material with a label under the

photoelectric sensor. – The LED illuminates.

➔ Press the NEXT key until the LED extinguishes. ➔ Make note of the value displayed when the LED ex-

tinguishes: Value of the label. If the LED does not extinguish even at the lowest value 1:

➔ Write down 1 as the value of the label.

➔ Calculating the setting value for CONT:

➔ Enter the calculated setting value using the NEXT or

PRIOR key.

➔ Save the value using the ENTER key and exit the

CONT function.

Test the setting:

➔ Pull the label ribbon through under the label stop

sensor. – The LED illuminates, if a label is under the photoe-

lectric sensor [61]. – The LED does not illuminate if only backing material

is under the photoelectric sensor.

[61] Backing material with a label under the label stop sensor;

LED (A) illuminates.

Page 61

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.7 Label distance (LPIT)

The label distance is defined as [62]: Label distance = label length + gap

The shape of the labels or reflective surfaces can cause a false signal to be sent from the label stop sensor. In such a case, the label distance must be manually set.

In the extended menu:

➔ Call up the LPIT function. ➔ Set the desired distance.

– Settings are possible in 0.1 mm steps:

Minimum: 5 mm

Maximum: 500 mm

➔ Confirm the value using the ENTER key and exit the

function.

[62] A Label distance

B Label length C Gap

ALS

380

➔ Press the FEED key to test the setting.

– A single label is dispensed.

Check setting

➔ Press the FEED key.

If the setting is correct: – A single label is dispensed at a constant dispensing

speed. The label completely separates from the

backing material and no wrinkling occurs.

If the setting value for LPIT is too large: – 2 labels are dispensed.

If the setting value for LPIT is too small: – A single label is dispensed. – Because the value for LPIT is too small, the control

unit prematurely anticipates a signal from the label

stop sensor. The missing signal triggers automatic

label compensation. This error is indicated if:

– The dispensing speed is excessively fast at

the trailing edge of the label.

– If a printer is connected, the device will print

more than once.

Page 62

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.8 Distance from the label stop

sensor to the dispensing edge (E–SS)

– Correct specification of the distance between the la-

bel stop sensor and the dispensing edge is a prereq-

uisite for setting the label stop position (STOD).

Set distance

➔ Adjust the distance between the label stop sensor

and dispensing edge. Round the measured value

up to a whole number value in mm.

In the extended menu:

➔ Call up the E–SS function. ➔ Input the distance value.

– Settings are possible in 1 mm steps:

Minimum: 12 mm

Maximum: 1000 mm – A maximum of 15 labels can be located between the

photoelectric sensor and the dispensing edge.

➔ Confirm the value using the ENTER key and exit the

function.

[63] A Distance between the label stop sensor and dispensing edge

ALS

380

➔ Check setting (see next page).

The minimum setting depends on the dispensing speed. – The greater the dispensing speed, the great-

er the minimum distance.

– If the minimum distance is not maintained,

the warning message W__7 appears.

Page 63

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

Check setting

➔ Call up the STOD function. ➔ Set the value for STOD to "0". ➔ Confirm the value using the ENTER key and exit the

function.

➔ Press the FEED key.

– A label is dispensed. – The leading edge of the next label should rest exact-

ly on the dispensing edge [64].

➔ Remove a single label from in front of the

sensor [65].

➔ Press the FEED key.

– A label is dispensed [66A]. – The gap on the label ribbon should be automatically

compensated for [66B]. – The leading edge of the following label should rest

exactly on the dispensing edge [66C].

[64] The leading edge of the following label should rest on the dis-

pensing edge.

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380

After the check: – Check the label stop position (STOD); refer to

page 42.

[65] Remove a single label from in front of the sensor

A B C

[66] After pressing the FEED key:

A A label is dispensed. B The gap on the label ribbon should be automatically compen-

sated for.

C The feed stops, the leading edge of the following label should

rest on the dispensing edge.

Page 64

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.9 Product length (PRDL)

A start signal can be prematurely triggered by the shape of the product or reflective surfaces. In such a case, the product length must be manually set.

Example [67]: If the product [D] reaches the product sensor [C], a start signal is sent and the machine dispenses a label. The recesses in the product trigger additional start signals; without the PRDL function, the product would be labelled several times. With the product length [A] set in the PRDL function, the machine ignores all start signals until the product has passed the dispenser head.

In the extended menu:

➔ Call up the PRDL function. ➔ Set the product length.

– Settings are possible in 1 mm steps:

Minimum: 5 mm

Maximum: 999 mm

➔ Confirm the value using the ENTER key and exit the

function.

To set the product length the same as the label distance:

➔ Set the value for PRDL to less than 5.

– The message AUTO appears on the operator panel. – The control system automatically sets the value for

PRDL to the value of the label distance (LPIT).

[67] A Product length

B Label C Product sensor D Product with recesses (arrows)

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C B

Page 65

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.10 Polarity of the product sensor

(P_S_)

The product sensor can optionally send the start signal, if – the leading edge of the product passes the

sensor [68A]. – the trailing edge of the product passes the

sensor [68B].

In the extended menu:

➔ Call up the P_S_ function. ➔ Set the desired polarity.

– Set the LEDG: Triggered by leading edge – Set the TEDG: Triggered by the trailing edge

➔ Confirm the setting using the ENTER key and exit

the function.

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4.4.11 Polarity of the label stop

sensor (S_S_)

The label stop sensor can optionally send the signal, if – the leading edge of the label passes the

sensor [68A] (standard setting, with automatic label

compensation). – the trailing edge of the label passes the

sensor [68B] (without automatic label compensa-

tion).

The function also allows the use of photoelectric sensors with different polarities.

In the extended menu:

➔ Call up the S_S_ function. ➔ Set the desired polarity.

– Set the LEDG: Triggered by leading edge – Set the TEDG: Triggered by the trailing edge

➔ Confirm the setting using the ENTER key and exit

the function.

A B

[68] Examples for different polarities of the product sensor:

A The sensor sends a signal at the product’s leading edge

(LEDG)

B The sensor sends a signal at the product’s trailing edge

(TEDG)

[69] Examples for different polarities of the label stop sensor:

A The sensor sends a signal at the label’s leading edge (LEDG) B The sensor sends a signal at the label’s trailing edge (TEDG)

Page 66

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.12 Number of unlabelled products

(MLAB)

If products do not get labelled, the operator receives the warning message W_0 at the operator panel. If too many products in a row do not get labelled, the machine stops. The error message E_11 appears at the operator panel. Using the MLAB function, you can determine how many products in a row are allowed to be unlabelled before the machine stops.

Example [70]: MLAB is set to value 2. The machine stops after three products in a row are not labelled. The error message E__11 appears on the operator panel.

ALS

380

In the extended menu:

➔ Call up the MLAB function. ➔ Set the desired value.

– Possible settings: 0 ... 10 products

➔ Confirm the setting using the ENTER key and exit

the function.

4.4.13 Electronic transmission ratio

of the RPM transmitter (EGRA)

– Compensation factor for RPM transmitter when op-

erating with automatic dispensing speed adjustment – Refer to chapter Automatic dispensing speed

(APSF), page 67. – For ALS 380 HS, refer to the Service Guide

[70] Three products in a row were not labelled.

Page 67

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

4.4.14 Advance print start (PDT)

When using a printer (optional): The printing process can be started even in the final phase of the label feed. In so doing, the printer stamp is already moving toward the label ribbon, even before the label has come to a standstill - this shortens the printing process. Using the PDT function, you can determine when (after how many motor strokes before label stop) the printing process will be started.

In the extended menu:

➔ Call up the PDT function. ➔ Set the desired value.

– Possible settings: 0 ... 50 motor strokes – For the setting 0000, the label stop and printer start

coincide.

➔ Confirm the setting using the ENTER key and exit

the function.

[71] The printing process starts while the label feed is still transport-

ing the next label.

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380

The printer stamp is blocking the label feed. – The printer stamp should first contact the la-

bel ribbon only after the label has come to a standstill.

➔ If the printer stamp prematurely contacts the

label ribbon, reduce the PDT setting value.

4.4.15 Printer dwell time (PDWT)

When using a printer (optional):

– Set the dwell time for the printer (printing time).

In the extended menu:

➔ Call up the PDWT function. ➔ Set the desired value.

– Settings are possible in 1 ms steps:

Minimum: 0 ms

Maximum: 1000 ms

➔ Confirm the setting using the ENTER key and exit

the function.

The printer stamp is blocking the label feed.

➔ When setting the printing time, ensure that

the printing process has finished before the next label feed begins.

– The greater the labelling speed, the less the

possible printing time.

Page 68

4OPERATION

4.4 SETTINGS IN THE EXTENDED MENU

ALS

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4.4.16 Tandem operation (TMOD)

Activate and deactivate tandem operation – Refer to chapter Tandem operation in the service

guide.

4.4.17 Applicator type (APPL)

When using an applicator (optional): Set the applicator type used or switch off the applicator.

– Refer to chapter Applicator (optional), page 52.

4.4.18 EP cylinder dwell time

(APT1)

When using an EP applicator (optional): Set the dwell time for the cylinders.

– Refer to chapter Applicator (optional), page 52.

4.4.19 Blowing time (APT2)

When using a blowing applicator (optional): Set the dwell time for blowing the label on the product.

4.4.22 Delete a product data bank

load (LOAD)

Selecting and loading a product data bank.

– Refer to chapter Product databanks, page 48.

4.4.23 Create/save product data bank

(SAVE)

Create a new product data bank.

– Refer to chapter Product databanks, page 48.

4.4.24 Delete a product data bank

(DEL)

– Refer to chapter Product databanks, page 48.

– Refer to chapter Applicator (optional), page 52.

4.4.20 Delay time (APT3)

When using an EP applicator (optional): Delay of the signal air blow

– Refer to chapter Applicator (optional), page 52.

4.4.21 Fine tuning of the dwell time

(APT4)

When using an applicator (optional): Fine adjust the dwell time of the applicator in combination with the automatic dispensing speed adjustment. By doing this, the accuracy of the label position on the product can be optimised.

– Refer to chapter Applicator (optional), page 52.

Page 69

4OPERATION

4.5 AUTOMATIC DISPENSING SPEED (APSF)

ALS

380

[72] A Speed sensor on the conveyor line

The automatic dispensing speed (APSF) makes it possible to automatically adapt the dispensing speed to the speed of the conveyor belt. The speed of the conveyor belt is picked up by a speed sensor and transmitted to the control system of the ALS 380. The control system calculates the permanent position and speed of the products. The resulting values are used for controlling label feed, unwinding, and rewinding and are constantly monitored and regulated. Fluctuations in the conveyor belt speed are automatically compensated for. If the conveyor belt stops, the label dispenser also stops.

The conveyor belt can stop even while a label is being dispensed. The label feed is then stopped as well. Only when the belt starts running again, does the label feed move the label to the next gap on the label ribbon.

Conveyor belt and label dispenser are operating in perfect synchronisation. As a prerequisite for this, the speed sensor must be correctly adjusted. Depending on the operating conditions, the relationship between the dispensing speed and the conveyor belt speed must be finely adjusted (the EGRA function).

Only servicing technicians are permitted to configure the label dispenser for APSF mode. For further information, refer to the Service Guide.

Page 70

4OPERATION

4.5 AUTOMATIC DISPENSING SPEED (APSF)

4.5.1 Electronic transmission ratio

of the RPM transmitter (EGRA)

– Required compensation factor for the RPM trans-

mitter – For ALS 380 HS, refer to the Service Guide

Setting the compensation factor

➔ Calculate the setting value for EGRA:

A= resolution of the RPM transmitter used in mm/pulse

– Possible settings: 100 ... 650 (factory setting: 600),

corresponds to resolutions from 0.10 ... 0.154 mm/

pulse

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➔ Call up the EGRA function in the extended menu. ➔ Input the calculated setting value and exit the EGRA

function.

The setting of the electronic transmission ratio affects the dispensing speed: – The smaller the EGRA compensation factor,

the greater the dispensing speed.

– When the EGRA has a low setting value and

a high conveyor belt speed, the allowable dispensing speed can be exceeded.

– If the dispensing speed is too great, the

warning message W__4 appears.

Test the setting:

➔ Remove the pressure roller unit at the dispensing

edge.

➔ Start the system.

– The labelling speed is too low if the product pulls the

label away from the backing material. – The labelling speed is too high if the label on the

product has folds in it.

Page 71

4OPERATION

4.6 APPLICATOR (OPTIONAL)

4.6.1 Principle of operation

If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator. In applicator mode, the applicator takes the label from the dispensing edge and carries it to the product.

The labeller can be equipped with various applicators, depending on the need. The following are possible: – Air Stream Applicator (pneumatic applicator):

Using suction, the applicator takes the label from the

dispensing edge, transports it until it is directly in

front of the product and then blows the label onto it. – Electro-pneumatic Applicator (EP Applicator):

The applicator uses suction to take the label from

the dispensing edge. Then a pneumatic cylinder ex-

tends and presses the label onto the product. – Reverse Electro-pneumatic Applicator (REVP

Applicator):

The applicator uses suction to take the label from

the dispensing edge. Then a pneumatic cylinder

with the label traverses into the application position

and waits there for the product. When the product

reaches the pneumatic cylinder, it presses the label

onto the product.

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By means of the APPL function in the extended menu, the controller is adjusted to the applicator currently in use

Page 72

4OPERATION

4.6 APPLICATOR (OPTIONAL)

4.6.2 Functions in the extended menu

Please observe the following

CAUTION!

Erroneous settings can lead to production setbacks, damage to the machine and system, and can even cause work-related accidents! – Only specially trained and instructed per-

sonnel may alter the settings in the extended menu.

Calling up the extended menu

➔ Simultaneously press the NEXT and PRIOR keys.

– CODE appears on the LED display.

➔ Enter the password [73].

– The following appears on the LED display for ap-

prox. 1 second: – The extended menu is active.

****

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380

[73] Key sequence (password) for the extended menu

Applicator type (APPL)

– Set the applicator type used or switch off the appli-

cator.

In the extended menu:

➔ Call up the APPL function. ➔ Set the desired type.

– Possible settings:

ASA Air Stream Applicator

EP: Electro-pneumatic applicator

REVP: Reverse electro-pneumatic applicator

DIR: Dispense directly from the dispenser head

without using the applicator.

➔ Confirm the setting using the ENTER key and exit

the function.

Page 73

4OPERATION

4.6 APPLICATOR (OPTIONAL)

EP cylinder dwell time (APT1)

– Dwell time for the EP cylinder

In the extended menu:

➔ Call up the APT1 function. ➔ Set the desired value.

– Settings are possible in 1 ms steps:

1 ... 7500 ms

➔ Confirm the setting using the ENTER key and exit

the function.

Blowing time (APT2)

When using a blowing applicator: – Dwell time for blowing the label on the product

ALS

380

In the extended menu:

➔ Call up the APT2 function. ➔ Set the desired value.

– Settings are possible in 1 ms steps:

1 ... 7500 ms

➔ Confirm the setting using the ENTER key and exit

the function.

Delay time (APT3)

When using an EP applicator: – Delay of the signal air blow.

The signal controls the air blow which blows the la-

bel onto the underside of the applicator. The value

for APT3 is the delay between the start of label dis-

pensing and activation of the air blow.

In the extended menu:

➔ Call up the APT3 function. ➔ Set the desired value.

– Settings are possible in 1 ms steps:

1 ... 5000 ms

➔ Confirm the setting using the ENTER key and exit

the function.

Page 74

4OPERATION

4.6 APPLICATOR (OPTIONAL)

Fine tuning of the dwell time (APT4)

When using an applicator in combination with the automatic speed adjustment (APSF): – Optimise the accuracy of the label position on the

product by fine tuning the dwell time for the applica-

tor.

Standard values: – Blowing applicators: approx. 25 ms – EP applicators: 60 ms … 100 ms, depending on the

length of the stroke

Prerequisite: – External RPM transmitter is calibrated (EGRA func-

tion)

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Determining and setting the exact value [74]:

➔ Call up the APT4 function in the extended menu.

➔ Set the setting value for APT4 to 1. ➔ Allow the conveyor belt (with products) to run slowly.

– Speed v

➔ Document the position of the label on the product:

Value: POS

➔ Increase speed of the conveyor belt to approx.

25 m/min (value v

➔ Document the position of the label on the product:

Value: POS

➔ Calculating the setting value for APT4:

➔ Input the calculated setting value. ➔ Confirm the value using the ENTER key and exit

the function.

Test the setting:

➔ Test the labelling accuracy at different conveyor belt

speeds.

= 10 m/min

in mm

[74] Label position in relation to the conveyor belt speed

- low conveyor belt speed

POS

- Label position at lower conveyor belt speed

- high conveyor belt speed

POS

- Label position at higher conveyor belt speed

➔ If necessary, correct the setting value for APT4:

– The greater the value for APT4, the farther forward

the label is applied. – The smaller the value for APT4, the farther to the

rear the label is applied.

Page 75

5AFTER OPERATION

5.1 CARE AND CLEANING

5 AFTER OPERATION

5.1 CARE AND CLEANING

5.1.1 Cleaning agents

ALS

380

5.1.2 Regular maintenance

Cleaning agents for rubber rollers: – Roller cleaner, ordering code 98925

If other cleaning agents are used, there is some risk of dissolving the rubber.

Cleaning agents for adhesive residues: – Label loosening spray

Other cleaning agents: – Isopropyl alcohol

CAUTION!

Isopropyl alcohol is flammable!

➔ Keep cleaning agents and used rags

away from open flames and other sources of ignition.

Isopropyl alcohol vapours can cause headaches, nausea, dizziness, or eye irritation.

➔ Only use it in well ventilated areas. ➔ Do not ingest it.

Prolonged contact with the skin depletes the skin’s natural oils, which can lead to irritation.

➔ Avoid contact with the skin if possible. If

you have sensitive skin, wear gloves.

The ALS380 labeller is designed to be maintenance-free. Nevertheless, to ensure long-lasting and reliable operating results, regular maintenance is required.

Depending on operating conditions, at least weekly:

➔ Carry out the cleaning and maintenance work de-

scribed in the following.

CAUTION!

Unsuitable cleaning agents can cause considerable damage to the machine!

➔ Do not use cleaning agents that could

damage or destroy the painted surfaces, lettering, the display, identification plates, electrical components, etc. Observe the information provided by the cleaning agent manufacturer.

➔ Do not use abrasive or plastic-dissolving

cleaning agents.

➔ Do not use any acidic or alkaline solu-

tions.

Page 76

5AFTER OPERATION

5.1 CARE AND CLEANING

Remove paper waste

➔ Wipe off all paper waste (dust) from all rollers and

edges.

➔ Clean the optics of the photoelectric sensors with a

soft brush or a soft tissue.

Braking brushes

➔ Loosen the stud bolts [75A] and remove the braking

brushes.

➔ Remove adhesive residues ➔ Turn the braking brushes and reinstall them so that

the side opposite the deformed bristles bears the

load.

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[75] Braking brush

Page 77

5AFTER OPERATION

5.1 CARE AND CLEANING

Capacitive sensor at the dispenser head

Only if the labeller is equipped with a capacitive sensor [76A] instead of the proper photoelectric sensor:

➔ Remove the knurled thumb screw [76B]. ➔ Remove 2 screws on the underside [77A]. ➔ Remove the upper part of the housing [78A]. ➔ Clean the sensor surfaces [78 arrows] with soft,

lint-free rags.

ALS

380

➔ Reassemble the sensor. ➔ Test the sensor adjustment.

[76] A Capacitive sensor

B Knurled thumb screw

[77] A Fastening screws for the housing on the underside

[78] A Upper part of the housing with sensor surfaces (arrows)

Page 78

6OPERATIONAL MALFUNCTIONS

6.1 WARNING MESSAGES

6 OPERATIONAL MALFUNCTIONS

6.1 WARNING MESSAGES

6.1.1 Please observe:

ALS

380

6.1.2 If a problem occurs

CAUTION!

Improper handling of the machine, especially changes to the settings, can lead to serious damage to the machine and system and can cause work-related accidents! – Only the responsible servicing techni-

cians or customer service personnel are authorized to make changes to the settings in the configuration menu.

➔ Ensure that the other settings are carried

out exclusively by specifically trained and knowledgeable personnel. Observe the expert symbols.

➔ Observe the additional information in this

operating instruction or in the service guide.

The control system detects a problematic or unacceptable situation: – A warning message is displayed on the operator

panel.

– As a rule, the labelling operation is continued, if the

operator does not stop the machine.

If the cause of the warning message is eliminated: – The warning code is no longer displayed.

6.1.3 Warning messages

Message Description Possible causes and remedies

W__0 Product was not labelled. ➔ Remove the unlabelled product.

Several labels are missing from the label ribbon:

➔ Replace the label roll if the error occurs frequently.

The distance between the products on the conveyor belt is insufficient:

➔ Increase the product distance. ➔ For circumferential labelling: Increase the rotation-

al speed.

The product triggers several start signals, caused by reflections, for example:

➔ Adjust the product length (PRDL).

When using a printer, the printing time is too long:

➔ If possible, decrease the printer dwell time

(PDWT).

➔ Start printing process before label stop (PDT).

Page 79

6OPERATIONAL MALFUNCTIONS

6.1 WARNING MESSAGES

Message Description Possible causes and remedies

ALS

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W__2 Memory errors

Factory settings are activated, see appendix.

W__3 Too many labels between label stop

sensor and dispensing edge.

W__4 Dispensing speed is too high.

This negatively affects position accuracy.

W__5 The roll diameter control (optional)

reports the end of the label roll.

CPU battery is discharged after a long shut-down period of the machine:

➔ Leave the machine switched on for some time to re-

charge the battery

If the accumulatorerror occurs frequently:

➔ Have the CPU battery replaced by the responsible

servicing technician.

Settings no longer available after software update. Settings must be input again by a servicing technician; refer to Service Guide.

Label stop sensor must be adjusted by servicing technician; refer to Service Guide.

➔ Reduce dispensing speed (VELO), if the warning-

message is frequently displayed for long periods.

For automatic dispensing speed (APSF): A check of the EGRA function by servicing technicians is required; refer to the Service Guide

➔ Insert new labelling material.

W__6 Data transmission error at the

V24 interface

W__7 Label position on the product too

close to the product’s leading edge and high dispensing speed

The cables, plug connections, and interface parameters must be checked by servicing technicians; refer to Service Guide

➔ Increase the setting value for POS, decrease dispensing

speed (VELO).

If this is not possible or the warning message reappears: The settings in the configuration menu must be checked by servicing technicians; refer to Service Guide.

Page 80

6OPERATIONAL MALFUNCTIONS

6.2 ERROR MESSAGES

6.2.1 If a malfunction occurs

ALS

380

If the control system detects a serious error: – The labelling operation is stopped. – An error code is displayed on the operator panel.

If the cause of the error has been eliminated:

➔ Acknowledge the error message by pressing the

ENTER key.

6.2.2 Error codes

Message Description Possible causes and remedies

E__1 The loop space is not filled. Label roll empty:

➔ Replace label roll.

Pressure roller not closed:

➔ Swing up the pressure roller on the drive roller unit’s un-

wind unit and return it to its position pressing against the roller. The pressure roller clicks neatly into its operating position.

Unwind unit drive defective: – Repair by servicing technician is required; refer to

Service Guide

The photoelectric sensor in the loop space does not actuate.

Reflective surface is dirty:

➔ Clean the reflective surface.

Use of very bright labels or Sensor potentiometer out of adjustment or Sensor defective: – Adjustment/replacement by servicing technician is

required; refer to Service Guide

Page 81

6OPERATIONAL MALFUNCTIONS

6.2 ERROR MESSAGES

Message Description Possible causes and remedies

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380

E__2 Label stop sensor does not detect

the labels.

Ribbon of labels does not run through the slot in the photoelectric sensor:

➔ Check the ribbon guide at the label stop sensor.

Label roll empty or more than 3 labels missing:

➔ Replace label roll as required.

Pressure roller not closed:

➔ Swing back the pressure roller dispenser head and return

it to its position pressing against the roller. The pressure roller clicks neatly into its operating position.

Insufficient labelling speed: – The product pulls the label off of the base material.

➔ Synchronise the labelling speed and product speed (VE-

LO function).

Other options:

➔ Manually adjust the sensitivity of the label stop

sensor (CONT).

➔ Check the label stop position (STOD). ➔ Check the label distance setting (LPIT). ➔ Check to see whether the feed motor at the dis-

penser head is running.

E__3 The photoelectric sensor in the loop

space does not detect the loop formation and the label stop sensor does not detect the labels.

E__4 Rewind unit problems Label roll empty:

E__5 Photoelectric sensor in the loop

space does not detect the loop formation and problem with the rewinding unit.

E__6 Label stop sensor does not detect

the labels and problem with the rewind unit.

Refer to E__1 and E__2; First check the loop formation.

➔ Replace label roll.

Label ribbon torn:

➔ Rethread the label ribbon at the rewind unit.

Rewinding motor runs too slowly or is defective: – Setting or adjustment by servicingtechnician is re-

quired; refer to the Service Guide

Refer to E__1 and E__4.

Label ribbon torn:

➔ Rethread the label ribbon at the rewind unit.

Page 82

6OPERATIONAL MALFUNCTIONS

6.2 ERROR MESSAGES

Message Description Possible causes and remedies

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380

E__7 Photoelectric sensor in the loop

space does not detect the loop formation; label stop sensor does not detect the labels and problem with the rewind unit.

E_10 Error in the applicator section (op-

tional)

E_11 Many products are not labelled. The

number of unlabelled products is greater than the amount set in the MLAB function.

Refer to E__1, E__2, and E__4.

Only when an applicator is used: Inspection of the compressed air connection and the neutral position sensor by servicing technicians is required; see the operating manual of the applicator.

The distance between the products on the conveyor belt is insufficient:

➔ Increase the product distance. ➔ For circumferential labelling: Increase the rotation-

al speed.

The product triggers several start signals, caused by reflections, for example:

➔ Adjust the product length (PRDL function).

When using a printer, the printing time is too long:

➔ If possible, decrease the printer dwell time (PDWT

function).

➔ Start printing process before label stop (PDT func-

tion).

E_12 Invalid setting value

Factory settings are activated, see appendix.

E_13 Label roll is completely consumed.

Labels are no longer detected at the label stop sensor.

E_14 Too many products between product

sensor and dispensing edge.

Several labels are missing from the label ribbon:

➔ Replace label roll

➔ Increase value for MLAB, if possible.

A serious memory error has occurred: – The control system needs to be reconfigured by a

servicing technician or Avery Dennison’s customer service; refer to the Service Guide.

➔ Replace label roll.

Product sensor located too far from dispensing edge: – A maximum of 7 products can be located between

the product sensor and the dispensing edge.

➔ Change the position of the product sensor. ➔ Subsequently correct the POS setting.

The product triggers several start signals, caused by reflections, for example:

➔ Adjust the product length (PRDL function).

Page 83

6OPERATIONAL MALFUNCTIONS

6.2 ERROR MESSAGES

Message Description Possible causes and remedies

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380

E_15 Short circuit

or Overload of outputs from CN10

ER-U Software error ➔ Press the ENTER key.

ER-I Software error

ER-D Software error

ER-T Software error

ER-A Software error

➔ Make note of all the information that is displayed on the

➔ Make note of what happened before the error occurred. ➔ Notify the responsible servicing technician.

A check of the connections and output signals by servicing technicians is required; refer to the Service Guide.

control panel.

Page 84

7APPENDIX

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7.1 FACTORY SETTINGS

7 APPENDIX

7.1 FACTORY SETTINGS

In the case of a memory error: – The message W__2 or E_12 appears on the

operator panel. – All databanks are deleted. – The settings of the machine are reset to fac-

tory settings [79].

Function Value Explanation

VELO 0500 Labelling speed: 50.0 m/min

STOD 0000 Distance between dispensing edge and label's leading edge: 0.0 mm

POS 0500 Distance between leading edge of product and label: 50.0 mm

POS 2 0000 Multiple labelling: Distance between the leading edges of the first and second label:

0mm

POS 3 0000 Multiple labelling: Distance between the leading edges of the second and third label:

0mm

VERT 0100 Dispensing speed = conveyor belt speed

CONT 0035 Sensitivity of the label stop sensor

E–SS 0064 Distance between label stop sensor and dispensing edge: 64 mm

LPIT 1000 Label distance: 100.0 mm

PRDL AUTO Product length = LPIT

P_S_ LEDG Product sensor: Triggered by leading edge

S_S_ LEDG Label stop sensor: Triggered by leading edge

MLAB 0000 Machine stops as soon as a product is not labelled.

PDT 0000 Label stop = Printer start

PDWT 0000 Printer dwell time: 0.0 s

EGRA 0600 APSF compensation factor for RPM transmitter with 0.166 mm/pulse

TMOD OFF Tandem operation off

Page 85

7APPENDIX

7.1 FACTORY SETTINGS

Function Value Explanation

APPL DIR Applicator mode off

APT1 0001 EP applicator dwell time 1 ms

APT2 0001 EP applicator blow time 1 ms

APT3 0000 EP applicator: Delay of the signal air blow: 0 ms

APT4 0001 Applicator operation with APSF – correction of the applicator dwell time: 1 ms

MDIR Turning direction of all motors for right-hand version

OMOD ON Machine goes into online mode (operation-ready) after switch-on

TAND 0000 Distance between product-sensors during tandem operation: 0.0 mm

SLEW 0100 Dispense speed during missing label compensation: 100 m/min

COMP ON Automatic label compensation activated

LABC

APSF OFF Automatic dispensing speed switched off

000 Label counter is reset to "0".

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380

BAUD NONE

PARI NONE

(Settings for data transmission to the serial interface)

SBIT 0001

NUMB 0001

PRNT STAM: Printer type used: Heat-transfer printer

[79] Factory settings

1) = Function in the configuration menu, see Service Guide

Page 86

7APPENDIX

7.2 PRODUCT DATA BANKS

Client/Order

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380

Function Data bank

POS

POS2

POS3

VELO

STOD

CONT

E–SS

LPIT

PRDL

P_S_

S_S_

MLAB

PDT

PDWT

PD01 PD02 PD03 PD04 PD05 PD06

EGRA

VERT

APPL

APT1

APT2

APT3

APT4

Date:

Signature:

Page 87

7APPENDIX

7.2 PRODUCT DATA BANKS

Client/Order

ALS

380

Function Data bank

POS

POS2

POS3

VELO

STOD

CONT

E–SS

LPIT

PRDL

P_S_

S_S_

MLAB

PDT

PDWT

PD07 PD08 PD09 PD10 PD11

EGRA

VERT

APPL

APT1

APT2

APT3

APT4

Date:

Signature:

Page 88

7APPENDIX

ALS

380

7.3 EC DECLARATION OF CONFORMITY

We, the:

Avery Dennison Deutschland GmbH Ohmstraße 3 D–85386 Eching

declare that we have designed and constructed the following designated machine in such a way that it complies with the basic safety and health requirements of the EC Directive.

Machine designation: ALS 380

Machine type: Label Dispenser

Serial number: Comprised of a running number (5 digits) +

date code (YY/MM) + ending (machine designation): –ALS380

(Example: 040060309–ALS380)

Relevant EU directives: Machinery Directive 98/37/EC,

EMC Directive 89/336/EEC Low Voltage Directive 73/23/EEC

Applicable Harmonized Standards, in particular:

Eching, 19 July, 2004

EN ISO 12100: 2003 (Safety of Machinery) EN 294: 1992 (Safety of Machinery) EN 61000–6–3: 2001 (Emission standard for residential, commercial and light industrial environments) EN 61000–6–2: 2001 (Immunity for industrial environments) EN 61000–3–2: 2000 (Limits for harmonic current emissions) EN 61000–3–3: 1995 + A1:2001 (Limitation of voltage fluctuations and flicker)

Markus Roderer (General Manager)

Page 89

Page 90

Avery Dennison Deutschland GmbH

Postfach 1163 85385 Eching Germany Telephone: +49-8165-925-0 http://www.machines.averydennison.com