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

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Page 1

ALS

204/206 256

USER MANUAL

Label Dispenser

Edition 7 04/2010

Page 2

Page 3

CONTENTS

ALS

20x 256

1 Please note

1.1 General notes

1.1.1 Validity and binding effect of this manual . . . . 5

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Technical status . . . . . . . . . . . . . . . . . . . . . . . . .5

Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1.2 Illustrations and descriptions. . . . . . . . . . . . . . 6

Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . 6

Dangers and risk notes . . . . . . . . . . . . . . . . . . . .6

Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Button symbols . . . . . . . . . . . . . . . . . . . . . . . . . .6

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Supplementary information . . . . . . . . . . . . . . . . .6

1.2 Safety instructions

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

Follow the instructions. . . . . . . . . . . . . . . . . . . . .7

Keep the product information at hand. . . . . . . . . 7

Ensure the required qualifications are met . . . . .7

1.2.2 Operational safety of the unit . . . . . . . . . . . . . 8

Proper usage. . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Protection against injuries by electrical current. .8 Protection against injuries by mechanical action.9

Protection against injuries by chemicals . . . . . . .9

1.2.3 Before beginning production. . . . . . . . . . . . . 10

Due diligence of the operating company and the

service technician . . . . . . . . . . . . . . . . . . . . . . .10

Due diligence of the user. . . . . . . . . . . . . . . . . .10

1.2.4 Safety notes on the unit . . . . . . . . . . . . . . . . 11

2 Product description

2.1 Overview

2.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.2 Control panel. . . . . . . . . . . . . . . . . . . . . . . . . 14

Operating LED. . . . . . . . . . . . . . . . . . . . . . . . . .14

Error LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

LCD display. . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.1.3 Connection arrangement . . . . . . . . . . . . . . . 15

Connections on the back of the device . . . . . . .15

Sensor connections. . . . . . . . . . . . . . . . . . . . . .16

2.1.4 Mode of operation. . . . . . . . . . . . . . . . . . . . . 17

2.1.5 Technical specifications. . . . . . . . . . . . . . . . 18

Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . .18

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Label sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . .18

Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Internal Interfaces . . . . . . . . . . . . . . . . . . . . . . .19

Status messages, test functions,

product profiles . . . . . . . . . . . . . . . . . . . . . . . . .19

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Environmental conditions . . . . . . . . . . . . . . . . .20

Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.1.6 Design models . . . . . . . . . . . . . . . . . . . . . . . 21

Right-handed version . . . . . . . . . . . . . . . . . . . .21

Left-handed version. . . . . . . . . . . . . . . . . . . . . .21

2.2 Options

External control panel . . . . . . . . . . . . . . . . . . . .22

Fixed dispensing edge. . . . . . . . . . . . . . . . . . . .22

Swivelling dispensing edge . . . . . . . . . . . . . . . .22

Spring-loaded dispensing edge. . . . . . . . . . . . .22

Pneumatic dispensing edge . . . . . . . . . . . . . . .23

V-shape dispensing edge . . . . . . . . . . . . . . . . .23

Adjustable dispensing edge holder . . . . . . . . . .23

Outer Diameter control sensor . . . . . . . . . . . . .24

Dust/Splash guard. . . . . . . . . . . . . . . . . . . . . . .24

Additional material guide disk . . . . . . . . . . . . . .24

Capacitive label sensor . . . . . . . . . . . . . . . . . . .25

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Applicator interface . . . . . . . . . . . . . . . . . . . . . .25

Narrow label spring kit. . . . . . . . . . . . . . . . . . . .25

2.3 Operating modes

2.3.1 Dispensing mode . . . . . . . . . . . . . . . . . . . . . 26

Stopping/Continuing the dispensing. . . . . . . . .26

Changing the counter reading . . . . . . . . . . . . . .26

Starting the unit in configuration mode . . . . . . .26

Counting labels backwards . . . . . . . . . . . . . . . .26

Online settings. . . . . . . . . . . . . . . . . . . . . . . . . .27

2.3.2 Configuration mode . . . . . . . . . . . . . . . . . . . 28

Function of the double-arrow button . . . . . . . . .28

Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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CONTENTS

ALS

20x 256

2.4 Function descriptions

2.4.1 Overview of functions . . . . . . . . . . . . . . . . . . 30

2.4.2 Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Function descriptions . . . . . . . . . . . . . . . . . . . .32

Quick setting . . . . . . . . . . . . . . . . . . . . . . . . . . .32

2.4.3 LABEL SETUP menu . . . . . . . . . . . . . . . . . . 32

2.4.4 MACHINE SETUP menu . . . . . . . . . . . . . . . 33

3 Before operation

3.1 Electrical connections

3.1.1 Power supply connection . . . . . . . . . . . . . . . 34

Checking the power supply setting . . . . . . . . . .35

Connecting the power cable.. . . . . . . . . . . . . . .35

3.1.2 Connecting sensors . . . . . . . . . . . . . . . . . . . 36

3.2 Inserting label material

3.2.1 Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . 37

3.2.2 Inserting a label roll. . . . . . . . . . . . . . . . . . . . 38

Removing spent backing paper. . . . . . . . . . . . .38

Removing glue residue . . . . . . . . . . . . . . . . . . .38

Inserting a new label roll . . . . . . . . . . . . . . . . . .38

3.2.3 Threading the label roll . . . . . . . . . . . . . . . . . 39

Threading guide . . . . . . . . . . . . . . . . . . . . . . . .39

Threading the label roll at the dispensing edge.40 Threading the label roll onto the drive roller . . .41

Fastening the label roll to the rewinder . . . . . . .41

3.3 Mechanical settings

3.3.1 Adjusting the unwinder’s core diameter . . . . 42

3.3.2 Positioning the pressure roller . . . . . . . . . . . 42

3.3.3 Positioning the label sensor . . . . . . . . . . . . . 43

3.3.4 Setting the dancer arm restoring force . . . . . 43

4 Operation

4.1 Start-up and shutdown

4.1.1 Turning on the unit . . . . . . . . . . . . . . . . . . . . 44

4.1.2 Starting label dispensing. . . . . . . . . . . . . . . . 44

Dispensing with a product sensor . . . . . . . . . . .44

Dispensing without a product sensor . . . . . . . .44

4.1.3 Stopping/Continuing the dispensing process 44

4.2 Configuration and monitoring

4.2.1 Function menu settings . . . . . . . . . . . . . . . . 45

Label pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Label stop position. . . . . . . . . . . . . . . . . . . . . . .45

Dispensing speed . . . . . . . . . . . . . . . . . . . . . . .46

Suppressing start signals . . . . . . . . . . . . . . . . .46

Label position on the product . . . . . . . . . . . . . .47

4.2.2 Monitoring functions. . . . . . . . . . . . . . . . . . . 48

Material end / Roll diameter. . . . . . . . . . . . . . . .48

Missing labels . . . . . . . . . . . . . . . . . . . . . . . . . .49

Material tear. . . . . . . . . . . . . . . . . . . . . . . . . . . .49

4.3 Using product profiles

4.3.1 What are product profiles?. . . . . . . . . . . . . . 50

4.3.2 Loading a product profile . . . . . . . . . . . . . . . 50

4.3.3 Storing a product profile. . . . . . . . . . . . . . . . 50

Selecting the memory location . . . . . . . . . . . . .50

Entering profile names. . . . . . . . . . . . . . . . . . . .50

4.3.4 Deleting a product profile. . . . . . . . . . . . . . . 51

5 After operation

5.1 Maintenance and cleaning

5.1.1 Replacing fuses . . . . . . . . . . . . . . . . . . . . . . 52

5.1.2 Cleaning agents. . . . . . . . . . . . . . . . . . . . . . 53

5.1.3 Regular maintenance. . . . . . . . . . . . . . . . . . 54

Removing paper debris . . . . . . . . . . . . . . . . . . .54

Renewal of the dust filter liner (ALS256) . . . . .54

6 Operational failures

6.1 Status messages

6.1.1 Types of status messages . . . . . . . . . . . . . . 55

Error messages. . . . . . . . . . . . . . . . . . . . . . . . .55

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

6.1.2 List of warnings . . . . . . . . . . . . . . . . . . . . . . 55

6.1.3 List of error messages . . . . . . . . . . . . . . . . . 56

7 Appendix

7.1 EC declaration of conformity

Page 5

1PLEASE NOTE

1.1 GENERAL NOTES

ALS

20x 256

1.1.1 Validity and binding effect of this manual Contents

The present manual refers exclusively to the ALS204, ALS206 and ALS256 label dispensers. It is written for the purpose of ensuring professional usage and calibration of the unit.

Prerequisites for the use and adjustment are the professional installation and configuration of the unit.

For any technical questions you may have that are not described in this manual, see:

£ The service manual of the label dispenser

£ Request a technician from one of our sales partners.

– Our sales representatives are available to assist

you, particularly with configuring the unit as well as in the case of malfunctions.

Technical status

Technical state: 12/2009 Software versions: 1.34

Avery Dennison reserves the right: – To make modifications to construction parts,

components and software, as well as to employ comparable components in place of the parts

specified, in keeping with technical advances. – To modify information in this document. No commitment will be made to expand these modifications to include any units delivered earlier.

Avery Dennison holds all rights to this manual and its appendices. Reproduction, reprinting or any other types of duplication, even of portions of this manual, may only be carried out with express written consent. Third persons, in particular competitors, should not be given access to the information in this manual.

Printed in Germany

Manufacturer

Avery Dennison Deutschland GmbH Ohmstrasse 3 85386 Eching, Germany Phone: +49-8165-925-0 Fax: +49-8165-925-231 http://www.machines.averydennison.com

1 PLEAS E NOTE

1.1 GENERAL NOTES

Page 6

1PLEASE NOTE

1.1 GENERAL NOTES

ALS

20x 256

1.1.2 Illustrations and descriptions Signs and symbols

Various information types are indicated in differ en t ways within the document in order to simplify readability and comprehension.

Sentences starting with an arrow are instructions and guidelines.

£ Perform the instructions one after another in the

specified order. The following information begins with a dash:

–Lists – Mode descriptions – Descriptions of prior steps – Prerequisites for following actions

Dangers and risk notes

Important directions that you must absolutely observe are particularly emphasized:

WARNING!

A warning refers to risks that can lead to serious injury or death! The warning contains safety measures to protect the relevant persons.

£ Always follow the instructions.

CAUTION!

A caution indicates risks that can lead to property damage or injuries to persons (minor injuries). The caution note contains instructions for preventing dama ge s .

£ Always follow the instructions.

Figures

Texts are accompanied by figures where necessary. Figures are indicated using figure numbers in [square brackets]. A capital letter after a figure number, for example [12A], refers to a specific section of the figure. Generally, the label dispenser shown is a right-handed version. The left-handed version is only shown where it is necessary to differentiate between the two.

Button symbols

– The buttons of the control panel are depicted as

symbols.

– The symbols are depicted with a ‘+’ (PLUS SIGN)

between them if more than one button is to be pressed. +

Parameters

Parameters are displayed in grey in the text with the following structure, MENU NAME > Function name.

Supplementary information

The expert symbol indicates actions that are only to be performed by qualified and specially trained personnel.

The information symbol indicates notes and recommendations, as well as additional information.

Equipment: – Equipment, for example lubricants or

cleaning agents

Page 7

1PLEASE NOTE

1.2 SAFETY INSTRUCTIONS

ALS

20x 256

1.2.1 Information and qualifications Follow the instructions

WARNING!

Safe and efficient operation of the label dispenser can only be guaranteed if you observe all necessary information.

Product liability and warranty claims can only be asserted if the unit was operated in accordance with the directions in the manual.

£ Before operating the unit, read the

operating instructions and all other notes carefully.

£ Observe the additional safety and

warning notes on the label dispenser.

£ Only permit competent people to operate

and configure the label dispenser.

Keep the product information at hand

With respect to this manual:

£ It should be kept at the location where the

unit is installed and be available to the operator.

£ It should always be legible. £ If the unit is sold, the manual should be made

available to the new owner.

£ The safety and warning notes affixed to the

unit itself must be kept clean and legible. Missing or damaged signs must be replaced.

Ensure the required qualifications are met

£ Ensure that only trained and authorized personnel

operate, configure and service the unit.

£ Only allow qualified and well-trained expert

personnel or service technicians to perform configurations.

£ The responsibilities with regard to operation,

configuration and maintenance should be cl ea rly defined and consistently maintained.

£ In addition, personnel should also be instructed on

a regular basis in matters of occupational safety and environmental protection.

Qualification for operation

The instruction of personnel using the unit must ensure that: – The operating perso nnel can use the unit on their

own and safely.

– The operating personnel can remedy small

operational disruptions on their own.

£ At least two people must be instructed in the unit’s

usage.

£ Enough label material must be provided for testing

and instructional purposes.

Qualifications for configuring

The configuration of the controls requires qualified expertise: – Personnel configuring the unit must be

acquainted with the functionality of the label dispenser.

– Personnel configuring the unit must be

acquainted with the modes of operation within the facility in which the label dispenser is integrated.

– The personnel configuring the unit must be

able to use the additional menus properly and appropriately for specific project requirements.

1.2 SAFETY INSTRUCTIONS

Page 8

1PLEASE NOTE

1.2 SAFETY INSTRUCTIONS

ALS

20x 256

1.2.2 Operational safety of the unit Proper usage

The label dispenser is a fully automatic unit for attaching self-adhesive labels to products or packaging. The company operating the unit must install it with suitable equipment to protect operating personnel from danger; for example, the danger of the hands or fingers being crushed by reaching in between the product and the dispensing edge.

WARNING!

Improper usage of the unit can cause accidents, property damage and production downtime!

£ Only use the unit in accordance with the

instructions specified in this manual.

£ Do not oper at e th e u ni t wit h ou t the

required safeguards.

£ Only configure the unit in accordance

with this manual and with the required care.

£ Only use original accessories. £ Do not make any modifications or

alterations to the unit.

£ Repairs to the device may only be

performed by authorised specialists who are aware of the risks involved.

Protection against injuries by electrical current

WARNING!

The machine operates using mains voltage! Touching live electrical parts may exp ose you to hazardous electrical currents and may lead to burns.

£ Only operate the unit once the housing

has been reassembled properly.

£ The machine may only be connected by

authorised specialists, who are aware of the risks involved.

£ Before cleaning, switch off the unit and

remove the power cable from the socket.

£ Only link the unit to devices that fulfil the

SELV (safety extra-low voltage) circuit requirements specified in EN60950.

£ Make sure that the power switch at the

machine is accessible.

£ In case of emergency, switch off the

device.

WARNING

The unit is not protected against splashing water in its standard model.

£ Keep the unit dry. £ If liquids have penetrated the unit, switch

it off and disconnect or unplug the power cable immediately. Inform a service technician.

CAUTION

A too high or low supply voltage can damage the unit.

£ Only operate the device using the system

voltage indicated on the nameplate.

£ Ensure that the mains voltage set on the

unit is the same voltage as that provided by the electricity supplier.

Page 9

1PLEASE NOTE

1.2 SAFETY INSTRUCTIONS

ALS

20x 256

Protection against injuries by mechanical action

WARNING!

Risk of injury due to moving and rapidly rotating parts!

– Long hair, loose jewellery, long slee ves,

and so on are not permissible when using the unit.

£ Sufficient protective clothing must be

worn.

£ Keep moving parts free from

obstructions even when the unit is not switched on, if there is a chance the machine might be turned on.

£ Switch off the machine before making

any mechanical settings.

£ Do not wear ties, loose clothing,

jewellery, wrist watches or similar items on your person when near the operating unit.

WARNING!

There is a risk that you may get your fing ers or hands crushed on the dispensing edge by products on the conveyor belt!

£ Never reach between the product and the

dispensing edge while the unit i s in operation or ready for operation.

£ Never reach behind the safety guard or

remove it while the unit is in operation.

Protection against injuries by chemicals

CAUTION!

Operating materials such as cleaning agents or the solvents in glues can be damaging to health.

£ Always follow the instructions, use and

safety regulations specified by the manufacturer!

Page 10

1PLEASE NOTE

1.2 SAFETY INSTRUCTIONS

ALS

20x 256

1.2.3 Before beginning production Due diligence of the operating company

and the service technician

£ Ensure that the following prerequisites are fulfilled in

accordance with the service instructions: – The machine is installed properly and configured in

accordance with the guidelines. – All required safety mechanisms have been installed. – The unit has performed at least one successful test

run. – The unit is connected to the power supply.

£ The users have the required personal protective

equipment, for example, a hairnet. Ensure that the

protective equipment is utilised correctly.

Due diligence of the user

£ Check that the safety installations are working

properly.

£ Inspect the machinery for any visible damage.

Report any ascertained defects immediately.

£ Use the required personal protective equipment

correctly, for example, wear a hairne t.

£ Remove any unnecessary materials and objects

from the operating area of the unit.

£ Ensure that only au th or ise d pe rs on s ar e with in th e

operating range of the machine.

£ Ensure that starting up the machine will not injure

anyone.

Page 11

1PLEASE NOTE

1.2 SAFETY INSTRUCTIONS

ALS

20x 256

1.2.4 Safety notes on the unit

CAUTION!

Warning notes on the unit represent important information for the personnel using it.

£ Do not remove warning notes. £ Replace any missing or illegible

warnings.

The ‘Pinch Point’ warning ] note warns you of the danger posed by the machine’s rota ting parts; they can trap items and draw them in.

The blue label ‘Read manual’ [2] demands that users read the unit instructions.

[1] Left: ‘Pinch Point’ warning. Right: Position of the warning note on the ALS 20x. Item number of the label: A5346.

WARNING

Pinch point.

Keep hands clear of rollers.

A5346

[2] Left: ‘Read manual’ notice. Right: Position of the notice on the ALS20x. Item number of the label: A5331.

Handbuch lesen! Read the manual! Lisez le manuel! Lea el manual! Legga il manuale!

Page 12

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

2.1.1 Components

[3] ALS204 Label Dispenser (right-handed version)

ALS256

2 PRODUCT DESCRIPTION

2.1 OVERVIEW

Page 13

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

A Control panel – For sending commands to the device and for

displaying operating states and error messages. – An optional external control panel can also be

connected to the device. B Dancer arm

– Keeps the label material stretched tight evenly. – Arrests the rotation of the material roll if tension

diminishes. C Dispenser

– Dispenser mandrel grasps the label roll. D Core diameter adapter

– For adjusting the diameter of the dispenser mandrel

to match the core diameter of the label roll. E Adjusting knob

– Turning this in a clockwise direction secures the

label roll on the dispenser. F Deflection rollers G Dispensing edge bracket H Label sensor

– Stops the label feed after a label has been

dispensed. I Pressure roller

– Prints the label once it is stuck to the product.

J Dispensing edge – Standard: (non-adjustable) L-shaped dispensing

edge

– The following options are available: V-shaped

dispensing edge, adjustable L-shaped dispensing edge, spring-loaded L-shaped dispensing edge, pneumatic L-shaped dispensing edge

K Drive roller – Drives the label material forwards.

L Pressure mechanism – Presses the pressure roller against the drive roller. – Prevents the backing paper from slipping through. – Releases automatically once the backing paper has

been drawn around the drive roller.

M Dancer arm – Controls the rewind speed.

N Rewinder – Rolls up the used backing paper.

O Release button – Pressing this button reduces the diameter of the

rewinder core.

– Allows the easy removal of the rewound backing

paper.

Page 14

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

2.1.2 Control panel Operating LED

Lights up green when the device is switched on.

Error LED

Lights up red when an error occurs.

LCD display

– Displays functions, configured values, operating

states and error messages. – What is displayed at any one time depends on the

operating status of the device; these screens are

explained in the section “Operating modes” on

page 26.

Buttons

The functions of the buttons depend on the operating status of the device; these functions are exp la i ne d in the section “Operating modes” on page 26.

Language

– The display language can be selected from a choice

of seven languages. – Default setting is English – For selecting another language see chapter

“Functions” on page 29

[4] The ALS20x control panel (in dispensing mode)

A Operating LED B Error LED C LCD display D Buttons

–

STATUS

Online

292

Labels

A B

Page 15

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

2.1.3 Connection arrangement

Connections on the back of the device

[5] Connections on the back of the device (ALS20x):

A Power supply connection B Network connection (Ethernet 10/100) C Serial interface (RS232) D Connection for external control panel (RS485)

E Plug-in card slot (CompactFlash cards) F USB device interface G PLC signal interface H Optional: Applicator interface

For information on connecting the unit, see section “Power supply connection” on page 34.

Page 16

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

Sensor connections

[7] Arrangement of the sensor connections (schematic) on the LH

(left figure) and RH (right figure) devices:

A Product sensor B Signal outputs (optional) C Signal inputs (optional) D Rotary encoder (for automatic speed adaption) E Roll diameter sensor F Label sensor G (ALS20x) Alternative label sensor H (ALS 256) Alternative label sensor

For information on connecting the sensors, see section “Connecting sensors” on page 36.

[6] Sensor connections on the ALS20x (RH)

START

PLC-OUT

PLC-IN

LABEL

ROTARY

ENCODER

CAP

CAP for 256

START

PLC-OUT

PLC-IN

LABEL

ROTARY

ENCODER

CAP

CAP for 256

RHLH

B C

D E

C B

E D

H H

Page 17

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

2.1.4 Mode of operation

In labelling mode, the strip is first pulled from the label roll around the dancer arm [8A], which consistently maintains even tension in the label strip. The feed roller [8D] behind the dispensing edge [8C] draws the strip across the dispensing plate. The label is unfixed from the backing paper on the dispensing plate and is pressed onto the product by the pressure roller [8B].

The feed roller drives the label strip forwards the length of one label and stops until the next product arrives at the dispensing plate. The strip feed is started by the product sensor mounted on the conveyor belt. The stop control provided by the label sensor on the dispensing edge ensures the feed is halted as soon as a gap is detected between two labels.

The spent backing paper runs from the dispensing edge around the drive roller [8D] to the rewinder [8E]. The dancer arm regulates the rewinding speed.

The entire operation of the label dispenser is controlled and monitored electronically. If errors occur, the device controls output an appropriate notification for the operator. If necessary, the labelling operating mode is halted automatically. An electronic signal is output at the same time. The signal can be fed to an external controller and evaluated.

[8] The ALS20x Label Dispenser is ready for operation in its

idle mode.

A Dancer arm B Pressure roller C Dispensing edge D Drive roller E Rewinder

Page 18

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

2.1.5 Technical specifications

Characteristics

1) The maximum usable dispensing speed depends on the label geometry. For details see separate performance matrix in the service manual.

2) At a dispensing speed range of 5m/min to the max. speed

Labels

3) Depending on the dispensing edge width.

Label sensor

Power supply

4) For more information on fuses, see section “Replacing fuses” on page52.

5) Not accessible for user or service technician.

Dispensing speed 1):

ALS204 ALS206 ALS256

max. 40m/min max. 30m/min max. 50m/min

Labelling halt precision

at the peeling edge:

±1 mm

Speed control: Fixed setting or automatic

speed adaption via the rotary encoder

Label material: Converted self-adhesive

label material with liner Internal rewinding yes Material width (including

backing paper)

ALS204 ALS206 ALS256

up to 110mm

up to 160mm

up to 160mm Label length: 5 to 600mm Label roll:

Winding direction Unwinder (outer) Ø: Rewinder (outer) Ø: Core (inner) Ø:

inner or outer

up to 300mm

up to 200mm

38.1/76.2 /101.6mm

(1.5/3 /4")

Distance to peel edge

L-shape dispensing edge: V-shape dispensing edge:

19mm 77mm

Transmission sensor: Wenglor OPT242-P800

optical, NPN

System voltage:

ALS20X

ALS256

110V (AC) at 60Hz power frequency (permissible tolerance ±10%)

230V (AC) at 50Hz power frequency (permissible tolerance ±10%)

100-240V (AC) at 60/50Hz power frequency (permissible tolerance ±10%)

Current consumption:

ALS20X

ALS256

max. 4A at 110V max. 2A at 230V

max. 4A at 100V max. 2A at 240V

Power consumption:

ALS20X ALS256

max. 460VA max. 460VA

Fuses:

ALS20X ALS256

F1, F2: T5AH 250V

Fuses integrated in the power supply

Page 19

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

Electronics

Interfaces

Internal Interfaces

6) Not yet available

Status messages, test functions, product profiles

Processor: 32Bit CPU MIPS Core RAM: 16MB ROM: 4MB Control panel: graphical display with

128x32 pixels, 2/4 lines,

5 buttons

Sensor interfaces for external sensors

Label sensor:

Alternative label sensor:

Product sensor: APSF-sensor (Rotary

encoder):

Stock sensor:

(plug in each case 4-

pin M12)

Wenglor OPT242-P800

optical, NPN, 24V, con-

trollable sensitivity

PNP/NPN, 24V

single-phase/two-phase,

PNP/P-P, 24V, max.

20kHz

PNP, 24V Internal sensor interfac-

es:

Material unwinder Pressure roller Dancer arm

Light barrier

not used

bi-phase light barrier en-

coder PLC interface

Outputs:

Inputs:

Sub D15, optically insu-

lated, optionally via two

8-pin M12 (separate in-

puts/outputs in each

case)

4x PNP, 24V, a maxi-

mum of 500mA/channel,

total permissible output

current: 1500mA

3x PNP/NPN, 24V

Data interfaces:

Serial:

Ethernet: USB:

CF card:

Control panel interface:

RS232C (Sub-D9), max. 115200 Baud

10/100 BaseT (RJ45) Device V1.1 (USB B),

‘Full speed’ operating mode, 12MBit/s

Slot for 1 CompactFlash card

RS485 (Mini DIN 6 connection) for remote control

RFID Connection for RFID

read/write unit (special equipement)

Applicator Interface Connection for Applicator

Interface (AI) board (special equipement)

Connector for additional motor driver

not used

Automatic halt, if ... the label roll is spent or

no gap was found. ...the max. admissible number of missing labels is reached.

Test functions: Automatic diagnostics

check when switched on Output of system data via

data interface

Status indicators: Label counter

Operating hours counter

Storage locations for product profiles:

up to 16

Page 20

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

Dimensions

6) Measurements without the dispensing edge br acket and dispensing edge

Environmental conditions

Integration

Certificates

– CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA – The regulation DIN EN 55022 demands for class A

devices the following text to be printed in the manual:

„WARNING: This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.“

– The FCC regulation demands the following

information text for class A devices: „NOTE: This equipment has been tested and found

to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense“

Width x height x depth:

ALS204 ALS206 ALS256

492 x 488 x 353mm

492 x 488 x 403mm

492 x 488 x 403mm Weight:

ALS204 ALS206 ALS256

36kg

38kg

40kg

Operating temperature: 5 to 40°C Humidity: 30 to 85%, (non-con-

densing) Noise

(at a distance of 1m):

72dB(A)

Protection class: IP 21

IP 65 special equipment

for ALS20X

Mounting positions: side / bottom / rear Labelling positions: top / side / bottom Dispensing edges: V-shape

L-shape

fixture 90° pivoting

Page 21

2PRODUCT DESCRIPTION

2.1 OVERVIEW

ALS

20x 256

2.1.6 Design models

The ALS20X and ALS256 label dispensers are available in two designs for differing conveyor belt d irections.

Right-handed version

– The products are transported from left to right [9]. – The dispensing edge is located on the right side. – Abbreviation: RH

Left-handed version

– The products are transported from right to left [10]. – The dispensing edge is located on the left side. – Abbreviation: LH

The label dispenser operation described in this manual is based on the right-handed version. The left-handed version is only taken into account if the explanations or figures of the designs differ significantly.

[9] Right-handed version

A ALS20X B Product on the conveyor belt C Labelled product

[10] Left-handed version

Page 22

2PRODUCT DESCRIPTION

2.2 OPTIONS

ALS

20x 256

External control panel

– An external control panel can be connected in

addition to the integrated control panel.

– An external control panel is useful if the standard

control panel is difficult to access due to the position in which the unit is installed.

Fixed dispensing edge

– The dispensing edge has a fixed connection to the

brackets.

– To adjust the vertical position, lift/lower the entire

device.

– The slope angle can be adjusted by rotating the

brackets (see the service manual for further details).

Swivelling dispensing edge

– The position of the dispensing edge can be adjusted

vertically.

– The device need not be moved to adjust the position

of the dispensing edge; the device’s mounting need not be dismantled.

Spring-loaded dispensing edge

– The dispensing edge is pivoted. A torsion spring in

the dispensing head presses the dispensing edge downwards and onto the surface of the product.

– Allows compensation for height differences

between the products or on the product surface.

[11] External control panel

[12] Standard dispensing edge

[13] Swivelling dispensing edge

[14] Spring-loaded dispensing edge

2.2 OPTIONS

Page 23

2PRODUCT DESCRIPTION

2.2 OPTIONS

ALS

20x 256

Pneumatic dispensing edge

– The dispensing edge is pivoted in the dispensing

head. Compressed air presses the dispensing edge onto the surface of the product.

– Allows compensation for height differences

between the products or on the product surface.

V-shape dispensing edge

Not for ALS256! – An alternative for applications which do not leave

enough space for the standard dispensing edge holder, which juts out to the bottom side.

– Is attached directly to the machine

Adjustable dispensing edge holder

Enables a vertical fine adjustment of the dispensing edge towards the product without moving the machine.

[15] Pneumatic dispensing edge

[16] V-shape dispensing edge

[17] Adjustable dispensing edge holder (pictured red resp. dark

gray)

Page 24

2PRODUCT DESCRIPTION

2.2 OPTIONS

ALS

20x 256

Outer Diameter control sensor

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

Dust/Splash guard

Available only for ALS20X. Additional sealing of the electrical connections an d of

the housing fulfils the requirements of the IP65 protection class [19].

Additional material guide disk

The additional material guide disk [20A] improves the lateral guiding of the material roll. This option is especially recommended, if very narrow material (< 30mm width) is processed.

[18] OD sensor (pictured red resp. dark gray)

[19] Dust/splash guard of the electrical connections (pictured red

resp. dark gray)

[20] Additional material guide disk (A)

Page 25

2PRODUCT DESCRIPTION

2.2 OPTIONS

ALS

20x 256

Capacitive label sensor

Optional sensor, required for processing transparent labels [21]. The sensor is mounted to the rods of the dispensing edge holder.

Printer

– If necessary, you can mount a hot stamp printer (not

available from Avery Dennison) onto the holder brackets of the dispensing edge.

– Example of use: Printing consecutive numbers onto

labels.

Applicator

If it is not possible to label directly from the dispensing edge, you can fit an applicator to the label dispenser. Various types of applicators are available that depend on the given requirements.

Simple applicators can be controlled directly via the PLC signal interface [5G] that is available as standard.

Applicator interface

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

Narrow label spring kit

Narrow label material may under certain circumstances tear off or expand in a way which results in poor labelling precision. In those cases, it is adviseable to install weaker dancer arm springs.

[21] Capacitive label sensor with bracket and cable.

Page 26

2PRODUCT DESCRIPTION

2.3 OPERATING MODES

ALS

20x 256

2.3.1 Dispensing mode

This is the operating mode of the unit when switched on. You can carry out the functions listed in the sections below.

If text such as ‘Prof 5 xxxxxxxx’ is displayed instead of ‘ONLINE’: – The ‘xxxxxxxx’ product profile (mem o ry

location 5) is activated.

– For more information, see the ‘Using product

profiles’ section.

Stopping/Continuing the dispensing

Stopping the dispensing:

£ Press the button.

– The dispenser stops. – One of the two texts appears:

1) Second line = scroll text.

Continuing the dispensing:

£ If the lower text is displayed: Remove the label from

the applicator.

£ Press the button.

Changing the counter reading

£ Set the counter reading using the MACHINE SETUP >

Dispense counter function.

Starting the unit in configuration mode

To start the unit in configuration mode:

£ Set MACHINE SETUP > Turn-on mode to ‘Offline’.

Counting labels backwards

To count dispensed labels backwards from a starting value to zero:

£ Set LABEL SETUP > Stop count. mode to ‘Enabled’. £ Use the LABEL SETUP > Label stop quan. function to

define the starting value.

ONLINE

Stopped. press

Ç key to start.

ONLINE

Stopped. remove label. press

Ç key to start.

[22] Control panel in dispensing mode (292 labels dispensed)

A Explanation of buttons in dispensing mode

–

STATUS

Online

292

Labels

2.3 OPERATING MODES

Page 27

2PRODUCT DESCRIPTION

2.3 OPERATING MODES

ALS

20x 256

Online settings

The machine is in dispensing mode. To switch to the online settings mode:

£ Press the button.

– The display shows the dispensing speed [23A] and

the start offset [23C].

– The button assignments are as shown on the

buttons.

– You can increase (‘+’ button) or lower (‘–’ button)

both settings in the dispensing mode [23D].

Dispensing speed: – Setting range:

ALS204: [5.0…40.0] m/min ALS206: [5.0…30.0] m/min

ALS256: [5.0…50.0] m/min – Display fix: The dispensing speed is constant. – Display var: The dispensing speed automatically

adjusts to the speed of the conveyor belt (‘speed

adaption’). Start offset:

– Setting range: [0.0…999.9] mm – The start offset indicates the distance between the

product sensor and the dispensing edge.

Dispensing manually

– To manually trigger the dispensing of individual

labels:

£ Press the button.

– Dispensing speed: As specified in the setting (see

above). To switch back to dispensing mode:

£ Press the buttons + .

[23] Control panel in the online settings mode

A Dispensing speed display (here: 12.2 m/min constant) B Dispense label button C Start offset display (here: 0 mm) D Explanation of buttons in online settings mode E Button to lower dispensing speed F Button to increase dispensing speed G Button to lower start offset H Button to increase start offset

–

STATUS

Speed

12.2 fix

Offset

0.0

ABC

EFGH

Page 28

2PRODUCT DESCRIPTION

2.3 OPERATING MODES

ALS

20x 256

2.3.2 Configuration mode

The machine is in dispensing mode. Switching to configuration mode:

£ Press the button twice.

– Display:

£ Press the button.

– Display:

– LABEL SETUP is the name of the first menu that is

currently active. – In configuration mode, the button assignments are

as shown below the buttons.

Function of the double-arrow button

To dispense individual labels:

£ Press the button briefly (less than two

seconds). – Dispensing speed: As specified in the configuration;

‘Speed Adaption’ is not active. To automatically calibrate the label length:

£ Hold down the button for a while (longer than

two seconds).

Menus

In configuration mode, you have access to several menus providing a fixed sequence of functions that can be carried out.

You can set the unit so that some of the menus a re not shown.

Figure [24] shows the button functions for switching between the individual menus and for leaving them.

OFFLINE

LABEL SETUP

[24] Menu selection and button functions in configuration mode.

A Button for triggering a dispensing procedure and for

starting the measurement of lengths.

B Explanation of buttons in configuration mode C Menus

STATUS

–

LABEL SETUP

MACHINE SETUP

INTERFACE. PARA

OFFLINE

I/O BOARD

APPLICATOR PARA

SERVICE/DIAGNOS.

SERVICE DATA

Page 29

2PRODUCT DESCRIPTION

2.3 OPERATING MODES

ALS

20x 256

Functions

Every submenu contains functions for setting the unit controls.

Figure [25] shows the button functions for changing settings using the MACHINE SETUP > Language function as an example.

[25] Button functions for setting the MACHINE SETUP >

Language function.

A Button to ‘Accept changes’ B Button to ‘Cancel changes’

MACHINE SETUP

Language English

Language German

MACHINE SETUP Store Prod.Prof.

MACHINE SETUP Language

Page 30

2PRODUCT DESCRIPTION

2.4 FUNCTION DESCRIPTIONS

ALS

20x 256

2.4.1 Overview of functions

[26] Functions menu – part 1 (grey shading = function is described in

the following).

1) Only appears if LABEL SETUP > Multi label mode = „2labels/start“ oder „3 labels/start“

2) Only appears if LABEL SETUP > Stop count. mode = Enabled

3) Only appears if MACHINE SETUP > Light sens. type = Wenglor

4) Only appears if MACHINE SETUP > Speed Adaptio n = On

5) Only appears if MACHINE SETUP > Tandem Operation = „Master“, „Flipflop master“ or „Slave“

6) Only appears if „Tandem Operation“ = „Master“ or „Master flipflop“ and if „Tandem Synch.“ = „UDP Tandem Port“

7) Only appears if MACHINE SETUP > OD Sensor mode = „Error“ or „Warning“

8) Only appears if INTERFACE PARA > NETWORK PARAM.> Time client = Enabled

LABEL SETUP MACHINE SETUP

(continued)

INTERFACE PARA

(continued)

Load prod.profil Dispenser type Light sens. type > EASYPLUGINTERPR Port address Gap detect mode Store prod.prof. Labelsen. InType Interface Ethernet speed Dispense speed Del. prod.profil Startsen. In.Typ Spooler mode MAC Address Slew speed Dispense counter Start disp. mode Dispenser ID no. SNMP Agent Label pitch Turn-on mode Start error stop Spooler size SNMP Password Lab. stop offset Language On inhibit enter Offline mode FTP server Start offset Access authoriz. On inhibit leave Interface delay FTP Password Product length Default values Apply key WEB server Multi label mode Factory settings Material end err > COM1 PORT WEB display refr. Label 2 offset

Store parameters Material end war n Baud rate WEB admin passw.

Label 3 offset

Auto Sensor Adj.

OD Sensor mode No. of data bits WEB supervisor p.

Miss. label tol. Sensor Adjust

OD Sens. polarity 7Parity Time client

Miss. label mode Speed Adaption Stop bits Time server IP

Stop count. mode Encoder Type

Data synch. Sync interval

Label stop quan.

Encoder Resol.

Frame error DHCP host name

Encoder Diameter

Rew. operation > NETWORK PARAM. Tandem Operation IP Addressassign Tandem Synch.

IP address

Slave IP address

Net mask

Tandem Distance

Gateway address

2.4 FUNCTION DESCRIPTIONS

Page 31

2PRODUCT DESCRIPTION

2.4 FUNCTION DESCRIPTIONS

ALS

20x 256

[27] Functions menu – part 2.

SIGNAL INTERFACE

(continued)

SERVICE/DIAGNOS. SERVICE DATA

(continued)

Interface mode > AI BOARD SIGNAL

Service > MODULE FW VERS. Manufacturer

> PLC SIGNALS

Applicator type Serv. data reset System version Work place End dispense mod Apply mode Sensor Test System revision Company name Disp. end delay Start mode Memory card test System date End pulse width Dwell time

Test functions Bootloader > DISPLAY DATA

Blow on time

Store diagnosis uMon Display version

> APPLIC. SIGNALS

Restart delay Data blocks del. Applicator int.

Display serial nr.

Applicator type Position timeout

Remote disp. vers.

Status outputs Apply comp. time > OPERATION DATA Remote disip. #

Apply mode Serv. operations Dwell time

> AI BOARD SIGNAL

Tot. mat. length > CF CARD SLOT

Blow on time

Status signals Dispensing cycl. Card in slot Restart delay Operation time Position timeout

> ACTIVE INPUTS > MEMORY DATA Apply comp. time Start signal > POWERSUPPLYDATA Ram memory size

Inhibit signal Type Flash mem size

OD sensor signal Version CompactFlash

Serial number Default values PS Temperature Standby+On time

9) Only appears, if Interface mode = „PLC signals“

10)Only appears, if Interface mode = -“Applic. signals“

11)Only appears if applicator type = PEP, „PEP Blow on“, „Reverse PEP“, BTS or „LA-TO timed“

12)Does not appear if applicator type = „LTP-LTPV“, PEP, „Direct dispense“ or LA-TO

13)Does not appear if applicator type = ASA, „Direct dispense“ or LA-BO

14)Only appears with AI board installed and if Interface mode = „Applic. signals“

15)Only appears with AI board installed and if Interface mode = „PLC signals“

16)Only appears with AI board installed

17)Only appears if remote display is connected

18)Only with plugged-in CF-card

> CPU BOARD DATA CPU identifier PCB Revision FPGA version MAC Address Serial number Production date PCB part number Board part numb.

Page 32

2PRODUCT DESCRIPTION

2.4 FUNCTION DESCRIPTIONS

ALS

20x 256

2.4.2 Notes

Function descriptions

The following chapters only describe those functions that are necessary for operating an ALS20x/256 that has been configured and set up. These functions are highlighted in grey in the overview.

Settings of functions that are not described in the following may only be changed by qualified service technicians. These functions are described in the service manual.

The settings range or the individual settings for a function are shown in square brackets. – The default value is italicised for functions

that have individual settings.

– Settings that consist of several words are

shown in quotation marks.

Quick setting

[28] Button combinations for quick setting of functions with a huge

value range.

2.4.3 LABEL SETUP menu

Load prod. profil function:

– Loads product profiles from the internal database. – Produ ct pr of ile s co ntain product-specific settings. – You can select a maximum of 16 product profiles. – You can only select product profile numbers that

have profiles already stored for them.

– See chap. “Loading a product profile” on page 50. Gap detect mode function:

– After one of the following events, the printer must

always search for the punch, that is initialize the label material: a

fter switching the device on; after

changing the label material.

– Settings: [Manual, „Autom. Forward“]

Manual: The operator has to initialize the material always manually by pressing the feed key several times.

Autom. Forward: The material initialization is always done automatically, if necessary.

Dispense speed function: – The speed at which the label is dispensed – Setting range:

ALS204: [5.0…40.0] m/min; default: 10.0 ALS206: [5.0…30.0] m/min; default: 10.0 ALS256: [5.0…50.0] m/min; default: 10.0

– See chap. “Dispensing speed” on page 46. Slew speed function:

– Feed speed during initialisation – Setting range:

ALS204: [5.0…40.0] m/min; default: 1.0 ALS206: [5.0…30.0] m/min; default: 1.0 ALS256: [5.0…50.0] m/min; default: 1.0

Label pitch function: – Label pitch = label length+space – Setting range: [5.0…600.0] mm – See chap. “Label pitch” on page 45.

Lab. stop offset function: – Stop position of the label on the dispensing plate – Setting range: [0.0…999.9] mm; default: 20.0 – See chap. “Label stop position” on page 45.

Start offset function: – Distance between the product sensor and the top of

the dispensing plate – Setting range: [15.0…2999.9] mm; default: 15.0 – See chap. “Label position on the product” on

page 47. Product length function:

– With this function activated, the machine ignores all

start signals, until the product has passed the

dispensing edge – Setting range: [0.0…1999.9] mm; default: 0.0 – See chap. “Suppressing start signals” on page 46.

Multi label mode function: – Settings: [Disabled, „2 labels/start“, „3 labels/start“]

Disabled: Each start signal causes printing of one

label.

„2 labels/start“: Each start signal causes printing of

2 labels.

Buttons Effect

+ Decrease value with 10fold speed. + Increase value with 10fold speed. + Reset value to lowest setting.

Page 33

2PRODUCT DESCRIPTION

2.4 FUNCTION DESCRIPTIONS

ALS

20x 256

„3 labels/start“: Each start signal causes printing of 3 labels.

Label 2 offset function: – Defines the distance of the 2nd label for the

LABEL SETUP > Multi label mode function (see above).

The distance is measured from the front label edge of the preceding label.

– Setting range: [x…9999.9]mm; Default: x, with

x = LABEL SETUP > Label pitch.

Label 3 offset function: – Defines the distance of the 3rd label for the

LABEL SETUP > Multi label mode function (see above).

The distance is measured from the front label edge of the preceding label.

– Setting range: [x…9999.9]mm; Default: x, with

x = LABEL SETUP > Label pitch.

Miss. label tol. function: – Missing label tolerance – The maximum permissible number of successive

missing labels on the label strip – Setting range: [0…10] mm; default: 1 – See chap. “Missing labels” on page 49.

Stop count. mode function: – Settings: [enabled, disabled]

Enabled: Dispenser counter counts backwards,

starting with the value that has been set using the

LABEL SETUP > Dispense counter function. When the

counter reaches zero, no further labels are

dispensed.

Disabled: The dispenser counter counts forwards,

which means that the dispenser counter is

incremented with each label that is dispensed. Label stop quan. function:

– After this amount of dispensed labels, the dispenser

stops – Function only appears, if LABEL SETUP >

Stop count. mode = „Enabled“

– Setting range: [0…99999]; default: 0

2.4.4 MACHINE SETUP menu

Store prod. prof. function:

– Storing a prod uct profile, see chap. “Storing a

product profile” on page 50.

Del. prod.profile function: – Deleting a product profile, see chap. “Deleting a

product profile” on page 51.

Start error stop function: – Determines how the machine responds in the event

of a product start error. A product start error o ccurs when a new start signal arrives before the current dispensing cycle has ended.

– Settings: [On, Off]

On: Start errors are issued. If a start error occurs, the device stops and displays a relevant error message. Off: Start errors are ignored.

Turn-on mode function: – The operating mode of the unit after it is turned on. – Settings: [Online, Offline]

Online: Dispensing mode Offline: Configuration mode

Language function: – Language of the displayed text – Settings: [English, French, German, Spanish,

Italian, Dutch, Danish, Polish, Turkish]

Material end err function: – Refers to the internal OD control. – Settings: [On, Off]

On: Material end triggers a status message. Off: Material end triggers no status message.

Material end warn function: – Refers to the internal OD control. – Defines the critical roll diameter. – Adjustment range: [50…500]mm; Default setting:

80mm

Page 34

3BEFORE OPERATION

3.1 ELECTRICAL CONNECTIONS

ALS

20x 256

3.1.1 Power supply connection

WARNING!

This machine operates using mains voltage! Touching live electrical parts may exp ose you to hazardous electrical currents and may lead to burns.

£ Make sure that the device is switched off

before you connect the power cable.

£ Only connect the unit to a grounded

power socket fitted to authorised standards.

£ (ALS 20X) Only operate the device with

the mains voltage set on the voltage selector switch.

£ (ALS 20X) Ensure that the unit is set to

receive the mains voltage supplied by your electricity provider.

£ (ALS 256) Only operate the device using

the system voltage indicated on the nameplate.

£ The power cable should not be more than

3 m long.

The device is only completely disconnected from the mains if the power cable is unplugged. Therefore:

£ Make sure the power supply socket is

accessible.

£ In case of emerg en c y, switch off the

device and disconnect the power cable!

[29] Power supply (A) on the ALS 20X

3 BEFORE OPERATION

3.1 ELECTRICAL CONNECTIONS

Page 35

3BEFORE OPERATION

3.1 ELECTRICAL CONNECTIONS

ALS

20x 256

Checking the power supply setting

ALS256: A power supply setting is not required.

The ALS20X Label Dispenser is suitable for operation with a power supply of 230V (AC) or 110V (AC).

If you are unsure of what mains voltage your local electricity supplier provides, refer to a qualified service technician.

£ Check to see that the voltage that has been set

conforms to the local mains voltage.

[31] Permissible mains voltages for both positions on the voltage

selector switch.

Changing the voltage setting:

£ Make sure that the power cable is

disconnected.

£ Slide the switch [30A] to the respective

opposite position.

– Insert a small screwdriver into the groove [30B] and

move the red insert horizontally to the opposite stop

position (to the left in Figure

[30]).

Connecting the power cable.

£ Make sure that the power switch [32A] is set to ‘O’

(off).

£ Using the supplied power cable, plug the unit into a

socket connected to the mains supply.

For more information on fuses, see section “Replacing fuses” on page 52.

Switch setting Permissible mains voltage

115 100–120V (AC) 230 200–240V (AC)

[30] Voltage selector switch on the ALS 20X (set to 230 V in the

figure)

A B

[32] Power cable (B) plugged in.

Page 36

3BEFORE OPERATION

3.1 ELECTRICAL CONNECTIONS

ALS

20x 256

3.1.2 Connecting sensors

£ Check whether the required sensors are connected

before turning on the unit [33]. The minimum required sensors:

– Label sensor (installation location: dispensing edge) – Product sensor (installation location: conveyor belt)

Additional optional sensors: – Rotary encoder (required for speed adaption) – External outer diameter checking sensor (provides

advance warning of the end of a label roll) – Alternative label sensor; for example, capacitive

sensor, used to detect transparent labels.

You can find further information regarding suitable sensor types, pin assignments, and so on in the service manual.

[33] Sensor connectors:

A Label sensor B Product sensor C Optional: Rotary encoder D Optional: Roll diameter check E (ALS 20x) Optional: Alternative label sensor F (ALS256) Optional: Alternative label sensor

C D

Page 37

3BEFORE OPERATION

3.2 INSERTING LABEL MATERIAL

ALS

20x 256

3.2.1 Prerequisites

– The label dispenser is turned off at the main

switch [34A] (switch set to ‘O’).

£ Check that the safety installations are working

properly.

£ Inspect the machinery for any visible damage.

Report any defects immediately.

£ Remove any unnecessary materials and objects

from the operating area of the unit.

£ Make sure that only authorised persons are within

the operating range of the machine.

£ Use the required personal protective equipment

correctly; forexample, wear a hairnet, safety

glasses.

[34] Main switch on the housing.

3.2 INSERTING LABEL MATERIAL

Page 38

3BEFORE OPERATION

3.2 INSERTING LABEL MATERIAL

ALS

20x 256

3.2.2 Inserting a label roll

WARNING!

Risk of injury due to moving and rapidly rotating parts!

£ Before inserting the label roll, ensure that

the device is turned off at the main switch.

£ Do not under any circumstances turn the

device on before the label strip is threaded in completely.

Removing spent backing paper

Assuming backing paper has gathered on the rewinder [35A] :

£ Press the release button [35B].

– The tensioning mechanism of the rewinder is

slackened.

£ Remove the rewound backing paper.

Removing glue residue

£ If necessary, clean the following components:

– Dispensing plate – Deflection rollers – Drive rollers – Pressure roller

£ Follow the directions provided in section

“Maintenance and cleaning” on page 52.

Inserting a new label roll

£ Push the material roll [36A] onto the unwinder as far

as it will go.

£ Rotate the rotary knob [36B] in a clockwise direction

until the label roll sits tightly.

£ Run the label strip around the dancer arm as shown

in the figure [36C].

[35] A Rewound backing paper

B Release button C Backing paper path

[36] Inserting the material roll – Part 1.

Page 39

3BEFORE OPERATION

3.2 INSERTING LABEL MATERIAL

ALS

20x 256

3.2.3 Threading the label roll Threading guide

[37] Threading guide for ALS20x/256 with L-shape dispensing edge *.

A Right-handed version B Left-handed version

[38] Threading guide for ALS20x/256 with V-shape dispensing edge

A Right-handed version B Left-handed version

*) Solid line: Path for label rolls with labels facing outwards. Dottet line: differing path for label rolls with labels facing inwards.

Page 40

3BEFORE OPERATION

3.2 INSERTING LABEL MATERIAL

ALS

20x 256

Threading the label roll at the dispensing edge

Fixed [39] (standard) and pivotable L-Shape dispensing edges:

£ Unroll around 1m of label strip and remove the

labels from it.

£ Pass the backing paper around the first deflection

roller [39A] and through the slot in the sensor [39B].

£ Feed the backing paper under the pressure roller

[39C] to the dispensing plate [39D].

£ Feed the backing paper around the dispensing plate

to the second deflection roller [39E]. Spring loaded [40] and pneumatic [41] L-Shape di spen-

sing edges:

£ Additionally pass the backing paper between the

two slim deflection rollers at the joint [40A] [41A].

[41] Path of the label strip at the pneumatic dispensing edge (option).

[39] Path of the label strip at the dispensing edge.

A 1st deflection roller B Label sensor C Pressure roller D Dispensing plate E 2nd deflection roller

[40] Path of the label strip at the spring loaded dispensing edge

(option).

Page 41

3BEFORE OPERATION

3.2 INSERTING LABEL MATERIAL

ALS

20x 256

Threading the label roll onto the drive roller

£ Open the pressure roller. To do so, rotate the lever

[42D] in a clockwise direction.

£ Feed the backing paper around the deflection roller

[42B], drive roller [42C] and the dancer arm [42A].

£ Close the pressure roller. To do so, rotate the lever

until it snaps in noticeably.

Fastening the label roll to the rewinder

£ Clamp the backing paper to the rewinder as shown

and tighten it [44].

£ Manually rotate the rewinder by one turn.

[42] Open the pressure roller.

[43] Close the pressure roller.

[44] Fastening the backing paper to the rewinder.

Page 42

3BEFORE OPERATION

3.3 MECHANICAL SETTINGS

ALS

20x 256

3.3.1 Adjusting the unwinder’s core

diameter

Tool: – 3 mm hexagon (Allen) screwdriver

The unwinder can be adjusted with core adapters [45B] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter:

– 38.1mm (1”) core

£ Unscrew the screws [45A] (2 for each adapter) and

remove the adapters. – 76.2mm (3”) core

£ Screw on the adapters, as is shown in Figure [45].

– 101.6 mm (4”) core

£ Screw on the adapters, as is shown in Figure [46].

3.3.2 Positioning the pressure roller

£ Open the pressure roller [47B]. To do so, rotate the

lever [47C] until the roller snaps up.

£ Release thumb screw [47A]. £ Align the pressu re rolle r ove r the ba ckin g pap er so

that it is centred.

£ Close the pressure roller. £ Screw the thumb screw tight.

[45] Core adapter positions for a core diameter of 76.2mm.

[46] Core adapter positions for a core diameter of 101.6mm.

[47] Setting the position of the pressure roller (B).

3.3 MECHANICAL SETTINGS

Page 43

3BEFORE OPERATION

3.3 MECHANICAL SETTINGS

ALS

20x 256

3.3.3 Positioning the label sensor

£ Release the thumb screw. £ Position the sensor along the axle in such a way as

to allow it to register the spaces between the labels.

The LED [48A] lights up when the sensor is positioned over a label.

3.3.4 Setting the dancer arm

restoring force

The unwinder dancer arm is preset in a way, that a wide range of label materials can be processed whithout having to change the dancer arms restoring force.

Even so, very narrow label material can under certain circumstances tear off or expand in a way which results in poor labelling precision. In those cases, the restoring force must be decreased.

Tool: 2.5mm hex socket screwdriver

£ Turn the adjusting screw [49A] on the dancer arm

left to increase restoring force.

£ Turn the adjusting screw [49A] on the dancer arm

right to decrease restoring force.

A service technician can restore the factory setting, see service manual chap. 9.4.3 section „Adjusting restoring force of dancer arm“.

If the problem still occurs, although the restoring force is already set to a minimum, there is the option of building in some weaker springs.

The springs must be built in by a qualified service technician. Instructions can be found in the service manual, chap. 9.4.3 section "Replacing dancer arm springs", „Narrow label kit“.

[48] Label sensor from Wenglor, model OPT242-P800

[49] Setting screw (A) at the unwinder dancer arm.

Page 44

4OPERATION

4.1 START-UP AND SHUTDOWN

ALS

20x 256

4.1.1 Turning on the unit

[50] Main switch (A) of the ALS 20x

£ Set the main switch [50A] of the unit to ‘I’ (On).

– The following messages are displayed during the

start process:

(machine type and firmware version)

– Once switched on, the ALS20x is in dispensing

mode, see section “Dispensing mode” on page 26.

4.1.2 Starting label dispensing

Dispensing with a product sensor

Once switched on, the ALS20x is in dispensing mode; this means that triggering the product sensor will cause a label to be dispensed.

Prerequisites: – The label length must be specified. – The product sensor must be connected.

– The sensors must be configured correctly

(PNP/NPN).

Dispensing without a product sensor

It is also possible to trigger the dispensing process without a product sensor:

– The machine is in dispensing mode:

£ Press the button.

– The machine is in configuration mode:

£ Press the button briefly (less than two

seconds).

4.1.3 Stopping/Continuing the

dispensing process

– The machine is in dispensing mode. Stopping the dispensing:

£ Press the button.

– The dispenser stops. – One of the two texts appears:

1) Second line = scroll text.

Continuing the dispensing:

£ If the lower text is displayed: Remove the label from

the applicator.

£ Press the button.

ALS204 RH

V 1.34

ONLINE

Label 0

ONLINE

Stopped. press

Ç key to start.

ONLINE

Stopped. remove label. press

Ç key to start.

4 OPERATION

4.1 START-UP AND SHUTDOWN

Page 45

4OPERATION

4.2 CONFIGURATION AND MONITORING

ALS

20x 256

4.2.1 Function menu settings

Label pitch

£ Switch to configuration mode

Calibrating the label pitch automatically:

£ Hold down the button for a while (longer than

two seconds). Or: Enter the label pitch manually:

£ Measure the label pitch [51C]. £ Call the LABEL SETUP > Label pitch function. £ Enter the measured value in millimetres.

Label stop position

Prerequisites:

– The label length must be specified.

The next label to be dispensed waits in the label stop position. Here it is useful if the label protrudes over the dispensing edge a little [52].

ALS20x/ALS256 labellers are pre-configured for use with the supplied label sensor. If this sensor is employed, the label stop position setting will only require minimal correction.

Correcting the default setting:

£ Call the LABEL SETUP > Lab. stop offset function.

£ Increase the value to increase the overhang or

lower the value to reduce the overhang. The value ‘0’ will cause the label to stop with its front

edge directly under the label sensor. The front edge of the next label to be dispensed sh ould

be flush with the dispensing edge:

£ Enter the distance [52A] between the label sensor

and the dispensing edge. The front edge of the label to be dispensed should

overhang:

£ Add the length of the overhang to the distance

between the label sensor and the dispensing edge.

[51] A Label web

B Label C Label pitch

[52] Label stop position (A)

4.2 CONFIGURATION AND MONITORING

Page 46

4OPERATION

4.2 CONFIGURATION AND MONITORING

ALS

20x 256

Dispensing speed

You can set the dispensing speed to a fixed value or you can configure it to automatically adjust to the speed of the conveyor belt (speed adaption). The second option requires you to connect a rotary encoder that measures and relays the conveyor speed to the dispenser.

Configuring a fixed value:

£ Use the two left buttons to set the speed in

dispensing mode (online settings) (see “Online

settings” on page 27).

Or use the function menu settings:

£ Call the LABEL SETUP > Dispense speed function and

set the speed you require. Configuring speed adaption:

£ Turn the function on by setting MACHINE SETUP >

Speed Adaption to ‘Yes’.

£ Set MACHINE SETUP > Encoder Resol. and

MACHINE SETUP > Encoder Diameter as

appropriate for the employed rotary

encoder.

– See the service manual for information on suitable

rotary encoders.

Suppressing start signals

A start signal can be prematurely triggered by the shape of the product or reflective surfaces, what can cause erroneous labelling. In case of a product causing unwanted additional start signals while the product passes the dispensing edge, those signals can be suppressed by setting function LABEL SETUP >

Product length to the product length.

Example [53]: 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; the product would be labelled several times. With the product length [A] set in the LABEL SETUP > Product length function, the machine ignores all start signals until the product has passed the dispensing edge.

[53] A Product length

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

Page 47

4OPERATION

4.2 CONFIGURATION AND MONITORING

ALS

20x 256

Label position on the product

Prerequisites:

– The label length must be specified. – The label stop position must be set.

Configuration in dispensing mode:

£ Use the two right buttons to set the start offset (see

“Online settings” on page 27). Or use the function menu settings:

£ Call the LABEL SETUP > Start Offset fu nction and set the

start offset.

– The label should be flush with the front edge of the

product:

£ Enter the distance between the product sensor and

the dispensing edge [54A].

– The label should be stuc k at a dist an ce from th e

front edge of the product:

£ Increase the start offset by the distance [55A] to the

product’s front edge.

[54] Distance between the product sensor (left) and the

dispensing edge (right).

[55] Distance (A) between the label and the product’s front

Page 48

4OPERATION

4.2 CONFIGURATION AND MONITORING

ALS

20x 256

4.2.2 Monitoring functions

While in dispensing mode, an electronic controller monitors the following functions:

Material end / Roll diameter

(OD = outer diameter) To enable a quick renewal of the material roll, the

machine can alarm the operator before the end of the material roll is reached. This provides the OD-control, which is available in two versions:

– Internal OD-control

The machine control elaborates the signals coming

from two sensors, which are integrated into the

material unwinder.

– External OD-control (accessory)

A light barrier attached to the material unwinder is

triggered, if the roll OD falls below a certain value. Depending on the configuration and setting of the

machine, different messages appear in case of material end or the roll diameter falling below the critical value:

[56] Messages for monitoring label stock.

1) If MACHINE SETUP > Material end err = „On“

2) If MACHINE SETUP > OD sensor mode = „Warning“

3) If MACHINE SETUP > OD sensor mode = „Error“

If a warning occurs:

– Labelling operation is continued.

£ Press the button, to delete the warning. £ Prepare for inserting a new material roll.

Material end Critical OD reached Error message Warning Error message

No OD-control Status num: 5001

No gap found

none none

Internal OD-control

Status num: 5002

Material end

ONLINE

Material low

none

External OD-control none

ONLINE

OD sensor warn.

Status num: 5065

OD material end

Page 49

4OPERATION

4.2 CONFIGURATION AND MONITORING

ALS

20x 256

If an error message occurs:

– The machine stops.

£ Press the button to delete the message. £ Remove the rewound backing paper. £ Insert a new material roll (see “Inserting a label roll”

on page 37).

Missing labels

A label missing from the label roll does not normally affect the dispensing operation, because the label feed continues until a label’s edge passes under the label sensor.

Nonetheless, it can be important that missing labels are reported. By configuring the function LABEL SETUP >

Miss. label tol., you can specify whether an error message

is triggered after one or several missing labels.

Material tear

If the material path tears, one of these two messages appears:

– Which message appears depends on where the

material path is torn.

– The machine stops.

£ Press the button.

Status num: 5002 Material end

Status num: 5140 Rewinder control

Page 50

4OPERATION

4.3 USING PRODUCT PROFILES

ALS

20x 256

4.3.1 What are product profiles?

Product profiles are memory locations that can store all the settings for the machine controls. For recurring production jobs, they allow you to quickly set the machine to the respective product.

– Number of memory locations: 16 – The memory locations are numbered. In addition,

you can also enter a text identifier for each memory

location (with a maximum of 9 alphanumeric

characters).

4.3.2 Loading a product profile

CAUTION!

Incorrect settings may lead to production problems and damage both the unit and the equipment.

£ Only staff who are qualified and specially

trained should set up product databases.

£ Call the LABEL SETUP > Load prod. profil function.

– The following message appears when no memory

location is occupied:

– Only occupied memory locations are displayed. – When memory locations are occupied, the memory

location that was loaded last is displayed first:

Above example: The profile with the ‘xxxxxx’ text

identifier has been stored at the first memory

location.

£ Press the or the button until the profile you

require appears.

£ Press the button to load the profile.

– The unit restarts afterwards. – Display after the restart:

(in dispensing mode, ‘ONLINE’ is replaced by the

current profile name).

4.3.3 Storing a product profile Selecting the memory location

£ Call the MACHINE SETUP > Store prod.prof. function.

– Display shown when all memory locations are

unoccupied:

– When memory locations are already occupied, the

memory location that was last active is displayed:

– A ‘*’ occurring after the memory location number

indicates that the memory location is already occupied (here by the ‘customer_xyz’ profile) .

£ Press the or the button until you retrieve the

memory location you require (1–16).

£ Press the button to activate the memory

location.

– The profile name flashes, and you can now replace

the name using any text you choose.

Entering profile names

Accepting the profile name ‘Product 1’ without changing it:

£ Press the button twice.

– The profile is saved. – Display:

Changing a profile name:

£ Press the button.

– Display:

– The underscore marks the active position.

£ Press the or the button to scroll through the

available characters until the character you require appears.

£ Press the button to accept the character.

– The underscore jumps to the next character.

£ Enter the next character in the same way. £ When you have entered the last character, press the

button.

Load prod. profil No setup avail.

Load prod. profil Prof 1 xxxxxx

Prof 1 xxxxxx Label 0

Store prod.prof. Prof 1 Product 1

Store prod.prof. Prof 5*customer_xyz

Store prod.prof. Storing…

Store prod.prof. Prof x _

4.3 USING PRODUCT PROFILES

Page 51

4OPERATION

4.3 USING PRODUCT PROFILES

ALS

20x 256

– The profile is saved. – Display:

– The product profile has now been saved.

4.3.4 Deleting a product profile

£ Call the MACHINE SETUP > Del. prod.profil function.

– The memory location that was active last is

displayed.

£ Press the or the button until you retrieve the

memory location you require (1–16).

£ Press the button to delete the memory location:

– Display:

– The product profile has now been deleted.

Store prod.prof. Storing…

Del prod.profil Clearing…

Page 52

5AFTER OPERATION

5.1 MAINTENANCE AND CLEANING

ALS

20x 256

5.1.1 Replacing fuses

This section counts only for ALS20X. The fuses at the ALS256 cannot be replaced.

WARNING!

The machine operates using mains voltage! Touching live electrical parts may exp ose you to hazardous electrical currents and may lead to burns.

£ Make sure that the machine is switched

off and the power cable is unplugged before removing the fuse insert.

CAUTION!

Risk of fire, if a wrong fuse type is inserted.

£ Only replace fuses with the type and

rating specified in this manual.

The F1 and F2 fuses protect the primary side of the transformer. At any given time, only one of the two fuses is active. Which fuse is active depends on the switch setting of the voltage selector switch.

[57] Relation between the switch setting of the voltage selector

switch and the active fuse.

The CPU board and sensors are protected by a separate fuse in the switching power supply that must/may never be replaced.

If either of the two fuses is not working properly, only the drive motors are affected; the display and sensors continue to operate as normal.

Tool: Screwdriver

£ Turn off the unit. Unplug the power cable. £ Rotate the fuse holder a few degrees anticlockwise.

– The fuse holder pops up.

£ Take the fuse out of the fuse holder. £ Replace defective fuse. £ Replace the fuse holder and rotate it clockwise,

while applying light pressure, until the slot is vertically positioned.

Required fuse type: – T5AH 250V

[58] Fuse holder (A) of the ALS 20x.

Active fuse Mains voltage Switch setting

F1 230V 230 F2 110V 115

5 AFTER OPERATION

5.1 MAINTENANCE AND CLEANING

Page 53

5AFTER OPERATION

5.1 MAINTENANCE AND CLEANING

ALS

20x 256

5.1.2 Cleaning agents

Cleaning agents for rubber rollers: – Roller cleaner, order number 98925.

If other cleaning agents are used, there is a chance the rubber may corrode.

Cleaning agents for metal deflection rollers: – Cleaning solvent, alcohol-based solvent,

isopropyl alcohol, spray for removing labels

Cleaning the unit’s housing: – Commercially available neutral cleaning

liquid

WARNING!

Cleaning solvent, alcohol-based solvent an d isopropyl alcohol are highly inflammable!

£ Keep the cleaning agents, as well as any

used cleaning cloths, away from open flames and other sources of ignition.

£ Do not smoke. £ Observe the safety instructions on the

container.

CAUTION!

Unsuitable cleaning agents can cau s e considerable damage to the unit!

£ Do not use any cleaning agent that could

damage or destroy the resin surface, labelling, display, nameplates, electrical components, etc. Observe the instructions of the cleaning agent manufacturer.

£ Do not use any abrasive or

plastic-corroding cleaning agents.

£ Do not use any acidic or alkaline

solutions.

Page 54

5AFTER OPERATION

5.1 MAINTENANCE AND CLEANING

ALS

20x 256

5.1.3 Regular maintenance

The label dispenser is designed to be maintenance-free. However, you should service the unit regularly in order to ensure reliable long-term operating results.

Removing paper debris

Depending on operating conditions, you should perform the following at least once a week:

£ Wipe the paper residue from the rollers and edges. £ Clean the sensor lenses with a soft brush or cloth.

Renewal of the dust filter liner (ALS256)

CAUTION!

An exhausted filter liner can cause the machine to overheat and to break down.

£ Replace the filter liner regularly, at least

in monthly intervals.

In case of overheating the machine, the error message „5026 MotorProtect CPU“ appears, see “List of error messages” on page 56.

£ Screw out the four thumb screws [59A]. Remove the

filter cover [59B].

£ Replace filter liner (article no. A8697). £ Assemble the filter cover and fix it using the thumb

screws.

[59] Dust filter at an ALS256.

A Thumb screws B Filter cover

Page 55

6OPERATIONAL FAILURES

6.1 STATUS MESSAGES

ALS

20x 256

6.1.1 Types of status messages Error messages

When an error occurs, the machine stops immediately and displays an error message on the control panel.

Error messages are displayed as follows:

[60] An example of an error message:

5144 = status number; this number makes it easier to identify the message. ‘Rewinder init’ = status text; a brief description of the error.

Error messages that are not described here may only be resolved by a qualified service technician.

When an error occurs that is not described here:

£ Press the button to delete the message. £ Switch the device off, wait 30 seconds and then

switch it on again. If the error reoccurs:

£ Request a service technician.

Error messages that are not mentioned here are described in the service manual.

Warnings

Warnings indicate less severe status than error messages. The labelling is not interrupted by a warning.

Warning format:

[61] Example of a warning:

„Materialend warn.“ = Warning text; a short description of what has caused the warning.

Setting back a warning:

£ Press the key (works earliest with firmware

versions > 1.10).

6.1.2 List of warnings

Status num: 5144 Rewinder init

ONLINE

Materialend warn.

Displayed text Meaning

Produktstartwarn New start signal during the

dispensing operation. Or: Several missing labels on the

web, which can not be compensated.

APSF speed warn. The conveyor speed exceeded

the max. speed of the dispenser.

OD Sensorwarning External OD-control:

Critical material roll diameter is reached.

Material low Internal OD-control:

Critical material roll diameter is reached.

Toomany products Too many products between

sensor and dispensing edge (max. 8 products are allowed).

6 OPERAT IONAL FAILURES

6.1 STATUS MESSAGES

Page 56

6OPERATIONAL FAILURES

6.1 STATUS MESSAGES

ALS

20x 256

6.1.3 List of error messages

Status Status text Cause Action to take

5000 Bus device – Device at I2C Bus cannot be

contacted.

– In most cases, this message appears

as the first in a series of two or three messages which narrow down the error more precisely.

£ Delete the mess ag e by pre ssin g the

-key.

£ Switch the machine off, wait 30

seconds and switch it back on.

£ If the error message

appears repeatedly, call in a servicing technician.

5001 No gap found – Material end, if no outer diameter

(OD) control is activated.

– The maximum limit for missing labels

was exceeded (LABEL SETUP >

Miss. label tol.).

– The machine is not correctly set for

the type of label (MACHINESETUP >

Light sens. type ).

– Label length is not correctly set

(LABEL SETUP > Label pitch). – Photoelect ric lab e l sens or is dirty. – Photoelectric label sensor is

incorrectly positioned. – Photoelec t ric labe l se ns or is not

connected correctly. – Photoelectric label sensor is

defective. – Rotary encoder is not adjusted

correctly.

£ Check the points listed above and

correct if necessary.

£ Press the key to confirm the

error message.

5002 Material end – Material end (if the internal OD-

control is activated).

£ Insert new label roll.

5026 Moto rProtect CPU – (ALS 256) Dust filter liner exhausted.

This leads to overheating the

machine. – (ALS 20X) Voltage selection switch

set faulty. – There are some more possible

causes, which require a qualified

service technician to cure.

£ Renew the dust filter liner. Let the

machine cool down

£ Check setting of th e vo ltage

selectioin switch.

£ Switch the machine off, wait 30

seconds and switch it back on.

£ If none of the above listed actions is

successful, search for technical assistance.

[62] List of error messages

Page 57

6OPERATIONAL FAILURES

6.1 STATUS MESSAGES

ALS

20x 256

5140 Rewinder control Rewinder control

During problem-free operation, the rewind unit dancer arm only moves a minimal distance around the "control position". This is the position the dancer arm takes up after initialisation of the machine.

– Any force applied that moves the

dancer arm from its control position.

Example: The feed motor is blocked;

the backing paper is not conveyed

quickly enough; as a result the

dancer arm is pulled upwards.

Example: The backing paper is torn;

the dancer arm springs downwards.

£ Press the key.

– This reinitialises the dancer arm

control; the dancer arm moves back into the control position.

5143 Rewinder Stop – This message appears when the

dancer arm was held against its

upper stop for more than two

seconds.

Effect:

Power to the rewinder motor is

switched off, so that the rewinder can

be turned easily by hand.

This effect is helpful when installing a new label roll, because the rewinder can be turned easily.

£ Press the key to confirm the

error message.

5145 Rewinder full This error can only occur if the

end of a new label roll was glued on to backing paper that had already been wound onto the rewinder.

– The maximum permitted diameter

(205mm) for the rewinder roll has

been reached.

£ Remove the rewound backing paper £ Press the key to confirm the

error message.

Status Status text Cause Action to take

[62] List of error messages

Page 58

6OPERATIONAL FAILURES

6.1 STATUS MESSAGES

ALS

20x 256

5147 Tandemsynch. Init This message can only appear

during tandem operation.

– Communication between the master

and slave machines is not

functioning.

£ Check, if the slave machine had

been switched on before the master machine - if not, repeat the switching on in the correct order (first slave, then master).

£ Check, if both machines are

connected with the tandem interface cable - if not, connect them. For detailed information, contact a service technician.

5152 Winding direct. The backing paper end is not correctly

attached to the rewinder mandrel.

£ Attach the backing paper web to the

rewinding mandrel as described in chap. “Fastening the label roll to the rewinder” auf Seite 41.

5200 Home position This message may appear when

operating the applicator. The applicator did not reach its home position (upper end position) within the intended time-frame.

– Applicator operation set, but no

applicator available. – The applicator is stuck. – Compressed air applicator:

Compressed air supply interrupted or

switched off. – Cable not correctly connected.

£ Set SIGNAL INTERFACE > Interface mode

to „PLC interface“.

£ Remove any obstructions £ Check compressed air connection

and reconnect correctly if necessary.

£ Check cable and connect correctly if

necessary.

5201 Touch Down The applicator lower end position

(Touch Down) was not reached in time.

6002 New prog. vers. New firmware has been loaded. This is a

message from the labeller that new firmware is available.

£ Press the Online button to confirm.

– All parameters are reset to their

factory settings.

6030 New Parameters New firmware was loaded with the result

that new functions have been added to the menu.

£ Press the Online button to confirm.

– Automatic reset is performed. – All parameters are reset to their

factory settings.

6207 No file card No compact flash card was found. £ Check whether a compact flash card

is connected. If the compact flash card was not connected until after the machine was switched on: Switch the machine off and back on again.

Status Status text Cause Action to take

[62] List of error messages

Page 59

6OPERATIONAL FAILURES

6.1 STATUS MESSAGES

ALS

20x 256

9022 No network link This status message can only appear

when Ethernet address assignment is set to DHCP (INTERFACE PARA >

NETWORK PARAM.> IP Addressassign). The

cause is almost invariably an incorrectly plugged-in network connector.

£ Check whether the network

connector is plugged in correctly, correct if necessary.

Status Status text Cause Action to take

[62] List of error messages

Page 60

7APPENDIX

7.1 EC DECLARATION OF CONFORMITY

ALS

20x 256

We,

Avery Dennison Deutschland GmbH Ohmstrasse 3

85386 Eching, Germany

herewith assert that we have designed and built th e de vice described in the following to conform with the basic safety and health requirements of the relevant EU directives.

Eching, 19. March 2009

Name of the devices: ALS 204, ALS 206, ALS 256 Device type: Label dispenser Serial number: Consists of a sequential number (five-digit) +

date code (YYMM) + ending (device name): –ALS204, –ALS206 or –ALS256

(Example: 040060309–ALS204)

Relevant EU directives: 2004/108/EC (EMC Directive)

2006/95/EC (Low Voltage Directive)

Other applicable, harmonised norms, in particular:

EN 60950-1/A11:2004 (Information technology eq uipment safety) EN 55022:2006 class A (Information technology equipment - Radio disturbance characteristics - Limits and methods of measurement ) EN 61000–6-2: 2005 (Immunity standard for industrial environments) EN 61000-3-2: 2006 (Limits for harmonic current emissions) EN 61000-3-3/A2:2005 (Limitation of voltage changes, voltage fluctuations and flicker)

Year of first CE marking: ALS204, ALS206: 2006

ALS256: 2007

Markus Roderer (General Manager)

7 APPENDIX

7.1 EC DECLARATION OF CONFORMITY

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Avery Dennison Deutschland GmbH

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