Avery ALS 380 User Manual
OPERATING MANUAL
Label Dispenser
ALS
380
Article number: A6392, Release 06.2005
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
Copyright notice . . . . . . . . . . . . . . . . . . . . . . . . . 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
1
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
2
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
3
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
Contents
The present manual refers exclusively to the ALS 380
Labeller and the high-speed ALS 380 HS version. The
manual is to be referred to for correct operation and adÂjustment 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:
âž” Refer to the Service Guide for the ALS 380 Labeller
or
âž” 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 malfuncÂtions.
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
OhmstraĂźe 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 previousÂly delivered machines is excluded.
4
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 variÂous types of information used herein are categorised
and identified with certain symbols.
Sentences that are introduced by an arrow contain proÂcedural instructions.
âž” 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 folÂlowed 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).
âž” The instructions must be followed.
Illustrations
When required, text passages are accompanied by ilÂlustrations. The reference to an illustration is indicated
by typesetting the [illustration number] in square brackÂets. 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 inÂstructions on how to safeguard possibly afÂfected personnel.
âž” 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.
âž” The instructions must be followed.
5
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.
G
C
H
B
E
A
F
D
[1] Definition of directional information
A Front
B Rear
C Upward
D Downward
E Left
F Right
G Clockwise
H Counter-clockwise
6
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!
âž” Read this operating manual thoroughly
and observe all notices prior to operation.
âž” Observe all additional safety and warning
notices attached to the labeller.
âž” Only allow qualified persons to operate
and adjust the labeller.
Information must be made available
This operating manual
âž” is to stored at the machine operating location and
made accessible to the operator.
âž” is to maintained in legible condition.
âž” is to be made available to the new owner if the ma-
chine is sold.
âž” 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
âž” Only allow the machine to be operated, adjusted
and serviced by instructed and authorised personÂnel.
âž” Adjustment tasks via the expanded menus as well
as programming and administration of product dataÂbases are only to be performed by qualified and apÂpropriately trained personnel or by the responsible
servicing technician.
âž” The responsibilities for operation, adjustment and
servicing of the machine must be clearly defined
and consistently maintained.
âž” Moreover, personnel are to be regularly instructed
about work safety and environmental protection isÂsues.
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.
âž” Train at least 2 person to operate the machine.
âž” 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 experiÂence:
– 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 inÂtegrated.
– Adjustment personnel must be able to cor-
rectly apply the functions in the expanded
menu system to appropriately address the
order-specific requirements.
7
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 operÂation planners with suitable safety devices so as to proÂtect 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 proÂduction!
âž” Only operate this machine in accordance
with information contained in this manuÂal.
âž” Do not put the machine into operation
without the required safety equipment in
place.
âž” 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.
âž” 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.
âž” Pull out the mains power connection plug
from the socket before cleaning and
maintenance.
The machine is not protected against
splashing water.
âž” Maintain the machine in a dry condition.
âž” In case fluids penetrate into the machine
interior, immediately switch off the maÂchine 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 rotatÂing parts!
âž” The following regulations always apply:
âž” Keep a distance from running machines. Wear
snug-fitting clothing and hair nets.
âž” Even when the machine is idle, maintain the area
clear of movable parts if the possibility exists that
the machine could start.
âž” Never lay tools or loose parts on the machine if the
possibility exists that the machine could start.
âž” Switch off the machine before performing mechani-
cal adjustment tasks.
âž” Do not wear ties, loose garments, jewellery, watch-
es or similar articles on the body when in the maÂchine vicinity.
CAUTION!
Danger of body part trapping and pinching at
the dispensing edge due to products moving
in the conveyor direction!
âž” Never reach between the product and dis-
pensing edge of running or operationÂready machines.
âž” During operation, never remove or defeat
the purpose of protective guards that preÂvent reaching into the machine.
Protection against chemicals
CAUTION!
Operational materials such as cleaning
agents or adhesive solvents may pose a
health risk.
âž” Rules, work guidelines and safety regula-
tions issued by the manufacturer must
absolutely be followed!
8
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
âž” 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.
âž” 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 exerÂcise care
âž” Verify flawless functioning of the safety equipment.
âž” Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
âž” Use personal safety gear in accordance with the
regulations, e. g. wear hair nets.
âž” Non-required materials and objects are to be re-
moved from the working area of the machine.
âž” Make sure that only persons authorised to work on
the machine are within the working area of the maÂchine.
âž” Make sure that no one will be placed in a hazardous
situation as a result of the machine startup.
9
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW
2 EQUIPMENT DESCRIPTION
2.1 OVERVIEW
2.1.1 Structural elements
ALS
380
B
C
A
M
N
D
E
F
G
H
I
J
O
[2] Right-hand version of the ALS 380 Labeller
K
L
10
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 unÂwind unit [2E] and the upper braking brush [2F]. An adÂditional 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 continuousÂly 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 moÂtor-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 conÂtrolled and monitored. If a malfunction occurs, the conÂtrol system sends a corresponding message to the
operator. If necessary, the labelling operation is autoÂmatically 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
11
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 RPMÂtransmitter
Labels
Label width
(incl. backing material): max. 155 mm
Label length at
maximum dispensing
speed:
Label roll
Outer diameter
Core diameter:
Distance from dispensÂing edge to label senÂsor:
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
1)
Ambient conditions
Temperature
Operation:
Storage:
Relative humidity: 30 % to 80 %,
5°C to 40°C
5°C to 70°C
not condensing
Dimensions
Dimensions
Width:
Height:
Depth:
Weight
ALS 380:
ALS 380 HS:
735 mm
795 mm
400 mm
50 kg
55 kg
Casing
Covering for the controlÂelectronics:
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/
1)
240 V
50 Hz / 60 Hz
vertically falling drops of
water, not protected
against sprayed water)
1 AC motor
1)
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)
12
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.
A
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
13
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 instrucÂtions based on the top-labeller right-hand deÂsign 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
14
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 possiÂble, 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.
15
2EQUIPMENT DESCRIPTION
2.2 OPERATOR CONTROLS
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
A
B
C
D
E
[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.
16
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 reÂsult in life-endangering currents through the
body as well as burns. Voltage continues to
be present in the housing even when
switched off.
âž” Only put the machine into operation when
installed in a correctly installed housing.
âž” Maintain the machine in a dry condition.
A
[8] Main switch on the housing
17
2EQUIPMENT DESCRIPTION
2.3 CONTROL SYSTEM
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, calÂibration technicians, or service personnel have several
options for adapting the machine's functions to current
requirements.
The LED indicator gives the operator feedback mesÂsages regarding the current operating state of the maÂchine. 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 reÂcurring 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 roÂtation. These settings are not to be changed in normal
operation. They may only be changed by servicing perÂsonnel or the responsible servicing technician.
To give the operator a better overview, the setting opÂtions for occasionally changing settings, task-specific
data, databanks, and basic settings are grouped toÂgether in menus: The standard menu, extended menu,
product databanks, and configuration menu. The folÂlowing table provides an overview of the range of funcÂtions of the standard menu, extended menu, and
product databanks. The configuration menu is deÂscribed in the service guide.
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and sysÂtem, and can even cause work-related acciÂdents!
– Only specially trained and instructed per-
sonnel may alter the settings in the exÂtended menu or access the product
databanks.
18
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
1)
EGRA
TMOD
APPL
APT1
APT2
APT3
APT4
LOAD
SAVE
DEL
QUIT
Activating a
menu
1)
Not ALS 380HS
Main switch + NEXT PRIOR + NEXT Main switch +
PRIOR
19
2EQUIPMENT DESCRIPTION
2.3 CONTROL SYSTEM
2.3.3 Monitoring functions
During labelling operation, the electronic control sysÂtem 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
C
A
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 corÂresponding message to the operator. If necessary, the
labelling operation is automatically halted. The maÂchine simultaneously sends a signal to the system conÂtroller.
B
[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
A
[10] Backing material with a label under the label stop sensor (A)
20
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
âž” Verify flawless functioning of the safety equipment.
âž” Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
âž” Non-required materials and objects are to be re-
moved from the working area of the machine.
âž” Make sure that only persons authorised to work on
the machine are within the working area of the ma-
chine.
âž” 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 rotatÂing parts!
âž” Before inserting the label roller, ensure
that the machine is switched off at the
main switch.
âž” Never switch on the machine before the
label ribbon has been completely threadÂed into position.
A
[11] Main switch on the housing
Remove the old backing material
If backing material remains on the rewinding [12A]
roller:
âž” Swing the lever [12C] at the rewinding roller over the
red [12B] point.
– The tension of the rewinding roller spreader mecha-
nism is relieved.
âž” Remove the rewound backing material.
Remove adhesive residues
âž” 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
A
B
C
[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
21
3PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL
Insert new label roll
Only top-labeller:
âž” Loosen the set-screw at the guiding rod [13C] and
swing the guiding rod to the side.
ALS
380
All design versions:
âž” Rotate the knurled knob [13B] clockwise, to retract
the chucking wedge [13A] in the unwinding spindle.
âž” If there is still an old roll core on the unwinding spin-
dle: remove the old roll core.
âž” Completely push on the new label roll.
âž” 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:
âž” Allow the dancer arm to lightly rest against the label
roll and
âž” swing it approximately 1 cm over the unwinding
spindle. The dancer arm must not be allowed to
touch the unwinding spindle.
âž” Tighten the set-screw at the guiding rod.
A
B
C
[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
22
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
23
3PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL
ALS
380
Thread the label ribbon at the unwind unit.
âž” Swing up the pressure roller [16B] and the braking
brush [16C].
âž” Thread the label ribbon around the deflection
roller [16E], dancer armroller [16A] and drive roller
unit [16D].
âž” Form a loop after the drive roller unit and guide the
label ribbon over the operator panel support [16F].
âž” Swing the pressure roller and web brake back into
position.
– The pressure roller and braking brush click into op-
erating position.
E
A
D
B C
F
[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
24
3PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL
Thread in the label ribbon at the dispensÂing edge.
âž” Swing up the pressure roller [17D] behind the dis-
pensing edge.
âž” Unthread approximately 2 m of label ribbon from the
label roll.
âž” Guide the label ribbon around the first deflection
roller [17A] and through the slot in the photoelectric
sensor [17B] for the dispensing edge.
âž” Guide the label ribbon around the dispensing edge
to the drive roller unit [17C].
âž” Thread the label ribbon around the drive roller unit
and the second deflection roller [17E].
âž” Swing the pressure roller back into operating posi-
tion.
ALS
380
A
E
B
D
C
[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
25
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