Avery ALX 720 User Manual
A
Release 4/09
rticle number: 0089999-29
Operators Manual
ALX 720
Contents
1. Important Notes........................................................................................................7
1.1 Overview.......................................................................................................................................7
1.1.1 Manufacturer......................................................................................................................7
Technical State.................................................................................................................. 7
1.1.2
Copyright............................................................................................................................ 8
1.1.3
Safety............................................................................................................................................ 8
1.2
1.2.1 General Safety Notes ........................................................................................................8
Warning Notes in the Text .................................................................................................8
1.2.2
2. Description ...............................................................................................................9
2.1 Mechanics ....................................................................................................................................9
2.2 Operator panels.......................................................................................................................... 12
2.3 Plug board ..................................................................................................................................14
3. Preparing the machine...........................................................................................17
3.1 Installation ..................................................................................................................................17
3.1.1 Unpacking of the unit....................................................................................................... 17
Connection of the machine.............................................................................................. 17
3.1.2
General setting ................................................................................................................17
3.1.3
Preparing the Dispenser.............................................................................................................18
3.2
3.2.1 Inserting material .............................................................................................................18
Defining label data........................................................................................................... 18
3.2.2
Label guide ...................................................................................................................... 19
3.2.3
Dispenser Setup.........................................................................................................................20
3.3
3.3.1 Stop position.................................................................................................................... 20
Fixed dispensing speed................................................................................................... 20
3.3.2
Automatic dispensing speed (APSF)...............................................................................20
3.3.3
Label position on the product........................................................................................... 21
3.3.4
Product data bank............................................................................................................21
3.3.5
Preparing Printing.......................................................................................................................21
3.4
3.4.1 Adjustment of foil unwind / rewind tension ......................................................................21
Positioning of full size gap sensor................................................................................... 22
3.4.2
Adjust position of print head ............................................................................................ 23
3.4.3
Adjust pressure of print head........................................................................................... 23
3.4.4
Exchanging the Printhead................................................................................................ 24
3.4.5
4. Operation ...............................................................................................................27
4.1 Insert label material ....................................................................................................................27
4.2 Threading of thermal transfer foil ...............................................................................................31
4.3 Initialise new label material for dispenser................................................................................... 32
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ALX 720
4.4 Control of dispense unit ..............................................................................................................33
4.4.1 Dispenser Menu selection................................................................................................33
Missing label function and web breaks ............................................................................33
4.4.2
Display and data input......................................................................................................33
4.4.3
Handling the print operation........................................................................................................37
4.5
4.5.1 New Start of Printer..........................................................................................................37
Restart of Printer..............................................................................................................37
4.5.2
Call of Program Version...................................................................................................37
4.5.3
Modes of operation - OFFLINE........................................................................................37
4.5.4
Modes of operation - ONLINE..........................................................................................38
4.5.5
Display messages printer.................................................................................................38
4.5.6
Maintenance ...............................................................................................................................40
4.6
4.6.1 Cleaning print head..........................................................................................................40
Cleaning of Print Roller ....................................................................................................40
4.6.2
Cleaning of foil guiding parts............................................................................................41
4.6.3
Dispenser maintenance ...................................................................................................41
4.6.4
5. Dispenser adjustment ............................................................................................43
5.1 Standard menu ...........................................................................................................................45
5.2 Extended standard menu............................................................................................................47
5.3 Configuration menu.....................................................................................................................54
5.4 Handling the menu......................................................................................................................55
5.5 Menu functions............................................................................................................................56
5.6 Product data bank.......................................................................................................................61
6. Printer adjustment..................................................................................................63
6.1 Printer parameter menu..............................................................................................................63
6.2 INFO: Info printouts.....................................................................................................................64
6.3 PRTP: Print parameter adjustments...........................................................................................65
6.4 IFAC: Interface Parameter..........................................................................................................68
6.5 SYSP: System Parameter...........................................................................................................70
6.6 JCLR: Clearance of Print Job .....................................................................................................77
6.7 SCLR: Clearance of Printer Buffer..............................................................................................77
6.8 OTHR: Others = Special Parameters .........................................................................................77
6.9 Print head temperature...............................................................................................................80
7. Remote programming ............................................................................................81
7.1 Data of the serial interface..........................................................................................................81
7.2 Interface commands ...................................................................................................................82
7.3 Programming of printer functions................................................................................................84
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8. Status messages....................................................................................................85
8.1 Printer messages........................................................................................................................85
8.2 Dispenser Error Messages.........................................................................................................91
8.3 Dispenser warnings....................................................................................................................92
9. Card plug in modules .............................................................................................95
9.1 Card hardware............................................................................................................................ 96
9.2 Memory types............................................................................................................................. 97
9.2.1 PROM card (Programmable Read Only Memory)........................................................... 97
EPROM card (Erasable Programmable Read Only Memory)......................................... 97
9.2.2
EEPROM or E²PROM (Electric Erasable Programmable Read Only Memory).............. 97
9.2.3
FLASH RAM / PROM card .............................................................................................. 97
9.2.4
RAM card (Random Access Memory)............................................................................. 97
9.2.5
Card use..................................................................................................................................... 98
9.3
10. Connections and signals........................................................................................99
10.1 Output signals............................................................................................................................. 99
10.1.1 Error and warning output................................................................................................. 99
Printer output ...................................................................................................................99
10.1.2
OD-Control output............................................................................................................ 99
10.1.3
Ready output ................................................................................................................... 99
10.1.4
Applicator modes......................................................................................................................100
10.2
10.2.1 Signals for direct dispense.............................................................................................100
Control signals for the ASA applicator...........................................................................101
10.2.2
Signals for the EP applicator .........................................................................................102
10.2.3
Applicator connector......................................................................................................103
10.2.4
Input signals .............................................................................................................................104
10.3
10.3.1 Product sensor............................................................................................................... 105
OD Control sensor.........................................................................................................106
10.3.2
APSF sensor.................................................................................................................. 107
10.3.3
Control signals............................................................................................................... 108
10.3.4
EMI ...........................................................................................................................................110
10.4
10.5 Electronic diagrams..................................................................................................................111
11. Technical specification.........................................................................................117
11.1 Label Material...........................................................................................................................120
11.2 Thermal transfer foil..................................................................................................................120
12. Adjustment...........................................................................................................121
12.1 Printer.......................................................................................................................................121
12.2 Dispenser..................................................................................................................................122
13. Index ....................................................................................................................124
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ALX 720
1. Important Notes
1.1 Overview
The 720 is a fully automatic print and apply machine. Handling is very easy and can be learned
with a minimum of training. For operation, only a few adjustments are necessary. The machine
is controlled by a microprocessor and because of its programmable functions it can be used in
many applications.
Except of cleaning the print head, rollers and the different sensor’s there is no periodical
maintenance necessary.
This manual should help you to operate the 720. In chapter 2 the machine is described and
many expressions are explained. For normal operating chapters 3 and 4 are important. All
other chapters give additional details of the machine.
The ALX 720 is available in a right- or a left-hand version. The expression right or left is related
to the direction of product transport. In the following, a right hand machine is explained. For the
left hand version all explanations have to be mirrored.
1.1.1 Manufacturer
For technical questions, particularly in case of problems, your local service organisation will be
pleased to help you.
This machine was built by:
Avery Dennison Deutschland GmbH
Ohmstrasse 3
85386 Eching
Germany
Tel. +49-(0)8165-925-0
FAX +49-(0)8165-925-231
1.1.2 Technical State
Technical State 4/09
Dispenser Software 7.0
Printer Software 1.68
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ALX 720
1.1.3 Copyright
© This manual and its contents are protected. Duplications of the manual are allowed only if
expressly permitted by the manufacturer. The manufacturer reserves the right to technical and
other alterations without prior notice. The publisher cannot warrant the accuracy of the content
of this manual.
1.2 Safety
1.2.1 General Safety Notes
1.2.2 Warning Notes in the Text
In this description, two types of notes can be found:
y Warning note – indicates a possible risque of injury for the user. Ignoring the warning can
lead to injuries or material damages.
Example:
y Special advice regarding the carrying out – please notice!
Example:
CAUTION! - The machine is connected to mains. Only authorised
personnel may open the cover. Operation without this cover is not
allowed.
Note: Please take note of the given notes and advices. They serve your safety
as well as the preservation of value of the machine.
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ALX 720
2. Description
This chapter explains the structure and the function of the 720 dispenser part. The expressions
used are explained here.
CAUTION! - The machine is connected to mains. Only authorised
personnel may open the cover. Operation without this cover is not
allowed.
2.1 Mechanics
The label material is unwound from roller (003). The maximum diameter of the label roll is 300
mm. Max. width is 100 mm. The material roll is guided by 2 removable plates (002). The guide
plate in front has to be pressed against the label roll. Behind the cap (004) of unwind mandrel
(003) an adjustment screw for the brake is located. The unwind brake avoids after run of the
label roll when the label drive stops. The dancer arm (011) keeps the material tight and the
acceleration forces low. The deviator roller (008) makes sure that the material is guided
correctly.
Note: For labels longer than 100 mm and in "side labelling applications" it is
recommended to use the optional available kit dancer arm controlled unwind brake.
This device avoids uncontrolled after run of label material. The brake should not be
fixed too tight, otherwise the motor may stall or the material web gets broken.
Behind the deviator roller (009) the material is guided to the printer unit. First it passes the both
opposite holder for the label sensor. The sensor could be positioned across the whole label to
get the optimised position. In one of the two red guides a sensor to detect end of material is
mounted. Behind the print unit the material is hold in a loop buffer. The loop is controlled by the
position of the dancer arm. If the loop is not filled, the printer starts to fill the loop again. At a
adjustable position all further starts of the dispenser are ignored. Behind the loop the material is
guided to the dispensing edge. The brush (006) keeps the material tight without disturbing the
movement. At the dispensing edge (010) the label sensor (007) is mounted. The label sensor
detects the gaps between labels. The label sensor comprises of a light source and a light
receiver. The sensitivity can be adjusted by the operators panel.
At the dispensing edge (010) the label is separated from the backing paper. By means of a soft
(005) roller the label is applied on to the product. Roller (012) makes sure that the material is
always guided properly around the dispensing edge. Drive roller (001) keeps the transport
speed of the material constant. Deviator rollers (012) guide the backing material around the
drive roller (001). The pressure mechanics (013) press the backing paper against the drive
roller (001).
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ALX 720
02 03
11
04
19
08
13
17
15
Figure 1 Layout 720
With the handle (015) you may open and close the pressure mechanics (013). When inserting
the material the pressure roller has to be opened. Dispensing is only possible when the handle
(015) is in the closed position. Via the deviator roller (016) the backing paper is guided to the
14
01
1012
06
07
05
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ALX 720
rewind mandrel (017). The cone between the 4 pins can be pulled out to allow the reward
backing paper to be removed.
Except for the drive roller (001) and the material brush (006) the 720 has no wearing parts. The
operator panel (019) is described in the next chapter.
A threading diagram is affixed to the front of the 720 which shows how the label material should
be threaded through the machine.
Screw (014) secures the position of the pressure roller (013) in a lateral direction. In order to
achieve a reliable run of the label web position, adjust the roller to the centre of the label web.
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ALX 720
2.2 Operator panels
There are two operator panels for handling the machine. The operator panel for the dispenser
is shown below, it has a 4 digit LED display and 4 membrane keys.
Figure 2 Operator panel dispenser
The 4 soft keys have following functions:
FEED By pressing this key one label will be dispensed. When the machine
displays INIT pressing this key will start initialisation of the machine. An
initialisation has to be made each time a new material is used. If the FEED key is
pressed and held as the machine is turned on then the machine carries out an
automatic initialisation of the label parameters "CONT" and "LPIT".
PRIOR This key moves up the menu or increases the value of a (Prior
function) parameter. If the up arrow key is pressed and held as the machine is
turned on the product menu is selected.
NEXT This key moves down the menu or decreases the value of a (Next
function) parameter. If the down arrow key is pressed and held as the machine is
turned on the standard menu is selected.
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ENTER: This key is used to enter or exit a menu point or to cancel a
warning or error message.
When the keys have different meanings, it will be explained in the relevant menu description.
The printer part is equipped with it’s own display – so you can handle the printer and the
dispenser completely independent. The operator panel for the dispenser is shown in , it has a 4
digit LED display and 3 membrane keys.
Figure 3 Operator panel printer
FEED / PRIOR By pressing this key one label will be dispensed, if OFF or
On is displayed. This key moves up the menu or increases the value of a (Prior
function) parameter.
NEXT This key moves down the menu or decreases the value of a (Next
function) parameter.
ENTER: Pressing this keys normally toggle between Online / Offline mode.
The key is also used to enter or exit a menu point or to cancel a warning or error
message.
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g
ALX 720
2.3 Plug board
On the side a plate contains all plugs for external connections. If you use the optional
connections, it is strongly recommended to do this by means of the optional available SUB-D
connectors. This ensures best EMI stability of the machine.
There is one unit include the mains switch, the mains cable socket and the fuses. The fuse
holder setting you have to select according to your local main voltage (100, 120, 220 or 240 V).
You carry this out by taking off the fuse holder and position the fuse holder insert accordingly.
serial interface printer
mains fuse block
mains power switch
mains power plu
Figure 4 Main switch and printer interface
The plug at the top of the plate are the connections to the dispenser unit. Standard execution in
this machine is one I/O plug prepared for the product sensor and for the applicator. There are
some more holes for optional functions. The connections of the plugs are described in chapter
“connections”.
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ALX 720
Applicator plug
Figure 5 Plugs for dispenser
Product sensor
Serial interface dispenser
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3. Preparing the machine
3.1 Installation
3.1.1 Unpacking of the unit
y Before removing the unit off the box, don’t hold the machine on the dispensing edge, printer
unit to prevent disadjustment off the machine.
y For mounting the machine, a complete system of holding tools is available. Ask your Avery
representative.
y Take care that the machine is safe and stable mounted.
y There are rotating parts on the machine. Do the necessary actions to prevent that anybody
can be caught from these parts.
3.1.2 Connection of the machine
Before connecting the machine to the mains, check the correct setting of the line voltage. For
the connection of sensor, applicators e.g. see the chapter connections. Fix all cables to prevent
accidents and damaging of cables. Have also a look to the EMI chapter for proper machine
operation.
For checking of correct operation of sensors, applicators use the check functions SCHK, I_CH
and O_CH.
3.1.3 General setting
Normally the setting is done, but before operation check and note the general dispenser
configuration: dispenser direction, machine type, applicator mode, and APSF function.
The printer function IFAC / PORT has to be set to RS23.
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3.2 Preparing the Dispenser
3.2.1 Inserting material
Insert your label material in the machine to follow the instructions in the chapter Operation /
Threading.
3.2.2 Defining label data
For correct dispenser operation, you have to tell the machine the length of the label and adjust
the label sensor. Normally this is done automatically. For this follow the instructions in chapter
Operation / Initialise material. For initialisation of the dispenser set the printer to OFF.
There are some reasons the automatic initialisation is not possible:
y Using another then the standard optical label sensor
y Label material with a low contrast ratio between label and backing paper
y Labels with holes inside the label
In this case you have to set one or both of the parameter manually. Activate the extended
standard menu to do the settings by:
y Pressing both keys NEXT and PRIOR simultaneously
Display: CODE
y Password CODE entering:
1 time pressing the key PRIOR FUNCTION
2 times pressing the key NEXT FUNCTION
3 times pressing the key ENTER
Display: LPIT
y Setting the label length
Enter the LPIT function by pressing ENTER. Measure the distance from one label edge to
the edge of the next label. Enter the value in mm by using the function keys. Press ENTER
to leave the function. See also the information below.
y Change the setting of the label sensor
If another label sensor then the Wenglor type will be used, call the CONT function and set
the value to any M006.
If the contrast ratio is low, follow the instructions to adjust manually contrast.
y To store the setting permanent leaves the menu with the quit function. If you power off the
machine without quit all modification are lost.
y By pressing the key FEED one label can be dispensed if you are in the parameter selection.
Setting LPIT manually
To initialise labels with cut outs such as the one shown below - the "LPIT" parameter should be
used to enter the label pitch of the label web.
All other label edges seen by the label sensor will be ignored until the distance adjusted in the
"LPIT" parameter has been fed through the label sensor.
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ALX 720
Label sensor
LPIT
real leading
edge of label
Sensor signals
Figure 6 Definition of LPIT
Manual adjustment of the CONT parameter
y Remove a label from the backing paper and slide it inside the sensor.
y Reduce the value with the PRIOR key until the LED switched on.
y Press the key NEXT until the LED switched off. If there are marks on the backing paper do
the measurement on this position.
y Note the value GAP xxx
y Slide the backing paper including label inside the sensor. Use the lightest position on the
label for the adjustment.
y Increase with the NEXT key the value until LED lights again. Note the second value GAP
yyy
y Calculate the contrast value by the formula (xxx + yyy) / 2 and set it.
y Manual adjustment is completed.
With a difference of less than 20 an operation with this kind of sensor is not possible
(sometimes two or more labels are dispensed).
3.2.3 Label guide
On some of the axles there are guiding clamps. Adjust the clamps near the machine so all have
the same distance to the front plate (31.5 mm). The outer clamps should be mounted that the
guide but not bend the label material.
The front of the dispensing edge has a rot, which can be adjusted for straighten the material
guiding. Switch the printer to OFF and spend several labels by pressing the dispenser FEED
key. If the material guiding is running out of the guiding way, adjust the rot by loosing two
screws at the dispensing edge.
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3.3 Dispenser Setup
For adjusting the dispenser function, set the printer to OFF.
3.3.1 Stop position
The first step is to adjust the stop position. This is the basic adjustment of the dispense
process. Also in case of problems with the machine check if the stop position is okay.
Figure 7 Stop position
The stop position should be adjusted so that the label stops at the dispensing edge or up to 3
mm behind.
For a correct operation of the automatic label compensation, they will compensate a missing
label on the web, first the distance between label sensor and dispensing edge has to be
defined. Do this by calling the DIST function in the configuration menu. Check the setting by
removing a label before the label sensor from the web. Give a start signal to the machine by
triggering the start sensor (not the FEED key) and see if the compensation is done on the right
position. Do the fine adjustment with the STOD function.
3.3.2 Fixed dispensing speed
The second step is to adjust the dispense speed. If an APSF sensor is used see 3.3.3.
If an applicator is used, the dispense speed has no influence to the dispense process. Continue
with 3.3.4.
Set POS to the distance between start sensor and dispensing edge. If installed remove the
roller to press the label onto the product. Now try to dispenser one product. If the label has
wrinkles reduce the speed VELO. If the product peels out the label, so the stop position of the
next label is before the last position increase the speed. Normally your dispense speed should
be a little bit higher then your product speed.
3.3.3 Automatic dispensing speed (APSF)
With an connected rotary encoder the dispensing speed follows the measured product speed.
To adjust the speed use the EGRA function located in the extended standard menu. The
measured speed will be displayed in the VELO function. Do the adjustment in the same way
described for fixed speed.
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3.3.4 Label position on the product
At least adjust the position of the label on the product with the POS function or with the STAD
function, if an applicator is in use.
3.3.5 Product data bank
Save your setting in one of the product data banks. If different products and / or labels are in
use up to nine different combinations could be stored. Define and store the different product
data. The select the product data bank mode by holding the PRIOR key during power on.
Switch back to normal mode by holding the NEXT key.
3.4 Preparing Printing
3.4.1 Adjustment of foil unwind / rewind tension
Insert the print foil according the instruction in the Operation chapter.
The torque of foil unwind-and rewind mandrels are adjustable by means of the red hexagon pin.
The foil should run free of wrinkles respectively should not be stretched (especially at drum
section) over the whole run from roll to roll.
Increase of torque at unwind/rewind mandrel Foil must not be stretched
Decrease of torque at unwind/rewind mandrel Foil must not have wrinkle
The factory adjustment covers a wide range of foil width which is the main factor for
the torque. Use of very narrow and very wide foil however may need a readjustment.
Figure 8 Adjustment of foil rewind
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ALX 720
Figure 9 Adjustment foil unwind
3.4.2 Positioning of full size gap sensor
The unit is equipped with a full size gap sensor. From the minimum label width (25,4 mm) to the
maximum the sensor can be moved to the wanted position.
As shown on the pictures below, the sensor can be moved in two parts – the lower side and the
upper side. Both should match so the beam can run from the diode to the transistor! If that is
not adjusted properly the sensor can not work!
Diode
Transistor
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ALX 720
Full size upper part
Full size lower part
3.4.3 Adjust position of print head
The zero line of the print head can be varied from 2 - 13 mm of the left material edge
CAUTION! - Print head must not be plugged off!
y Loose screw at centre of print head axle and set print head to required position.
y Fix screw at print head
y Loosen black plastic disk at foil rewind and unwind mandrel by means of 2 mm allen key
y Adapt them both to position of print head zero line and tighten again
3.4.4 Adjust pressure of print head
Different material width may require different pressure of print head to material in order to
optimise the print quality.
y 3 grades are available.
y Rotate the adjustment disk by means of a coin or screwdriver to the required position.
CAUTION! - Select pressure only as high as necessary for the best print
quality. Too high pressure may lead to damages at the print head.
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ALX 720
thin media / small media
medium media / medium
thick media / wide media
Figure 10 Adjustment print pressure
3.4.5 Exchanging the Printhead
CAUTION! - The print head is an electronic module and highly sensitive to
static impacts. For that reason discharge your static potential before going in
contact with print head by gripping the base plate of the printer. If print head is
readjusted at axle mark its position accordingly.
• Disconnect unit and pull off mains plug.
• Remove material and foil.
• Remove plugs from print head in horizontal direction.
CAUTION! - Remove cable from print head not until 3 minutes from
disconnection of unit.
y Loosen the 2 red marked screws at fixation of print head.
y Loosen screw at centre of print head axle - until the print head fixation can be rotated
clockwise.
y Let the print head down to print roller and rotate the fixation clockwise.
y Draw print head carefully out of the print module.
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ALX 720
CAUTION! - Metal objects must never get in contact with the dot line. Do not
touch print head at dot line or connectors.
y For reassembling put the print head on the 180° rotated fixation, positioning is done by
y Keep print head and fixation together with fingers, rotate anticlockwise to print roller.
y Re fix print head by means of the 2 red marked screws at fixation bar.
y Put print head on axle to former position and fix screw again.
means of the 2 upright bolts.
Note: Before mounting notice the resistor value of the print head-noted at print
head. Special care is to be taken that print head is supported flush on mounting
plate.
Note: The screw enters a non visible gap at the axle, which ensures the correct
position of the print head. Factory adjustment is flash with the inner black plastic
bushing.
y Plug on the 2 connectors to print head.
y When exchanging the print head the value of the head resistor has to be keyed in after
restart.
CAUTION! - Entry of an incorrect value may lead to damage of print head!
y Repositioning of print head to print roller
Production tolerances at print head may cause to move the print head in or versus print
direction. This is performed by twisting the little screws at the guiding tooth when fixing
screws are loose (tools are supported with printer). The optimal position can be found by
print only !
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ALX 720
4. Operation
CAUTION! - Be careful on operation, fingers, hair, clothes, jewellery, etc. may
be caught by and get into rotating axles.
4.1 Insert label material
Before threading the new material, the waste paper should be removed. In the printer the old
material can be removed by
y pressing the red lift lever and drawing the material backward.
y pressing the ON/OFFLINE and NEXT key simultaneously the material will be transported
CAUTION! - Insertion/exchange of foil and material should be carried out only
by especially instructed personal.
backward.
Threading of the label material is shown down below on the threading diagrams for the
right-hand and the left-hand version.
Stuck to the side plate of the 720 is the threading diagram, which shows the correct mounting
of the label web.
left hand version right hand version
Figure 11 Threading diagram
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ALX 720
y Switch printer to OFFLINE mode and lift print head by brief pressing of the FEED key. Open
front cover.
y Hang document material in reel holder in a way to ensure unwinding that label in the printer
section is on the top. Put outer guide disk onto mandrel. The 2 guide plates keep the label
roll reliably in position on the unwind mandrel.
y Guide material around the dancer arm.
y Press the red lift lever at the right, outer end of the print module in order to lift the pressure
rolls of the feed roller and insert material below the print head. Adjust both pressure roll
units symmetric to material width so that material moves smoothly.
y Labels behind the dispensing edge should be removed. The material brush has to be
positioned in a way, that the material is kept tight. From time to time it is recommended to
reverse the mounting of the brush while you are loading a new label roll.
y Adjust the pressure roller before the rewind, so that it is right in the middle of the material.
Close the pressure roll and turn the roll 2 or 3 times, so that the material is threaded. Check
that the material is guided straight.
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4/09 Page 29 Operation
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Figure 12 Threading
4/09 Page 30 Operation
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