Avery Dennison ALS 321, ALS 421 User Manual

Release 2/08

A

rtikelnummer: 0089999-08

Operators Manual

ALS 321/421

Release 2/08 Page 1 Important Notes

Contents

1. Important Notes........................................................................................................3

1.1 Overview.......................................................................................................................................3

1.1.1 Manufacturer......................................................................................................................3

1.1.2

Copyright............................................................................................................................ 3

1.2

Safety............................................................................................................................................ 4

1.2.1 General Safety Notes ........................................................................................................ 4

1.2.2

Warning Notes in the Text .................................................................................................4

1.2.3

Operator’s duty of care ...................................................................................................... 5

1.2.4

Concrete security regulations and symbols used..............................................................6

1.2.5

Security measures during normal operation...................................................................... 7

1.2.6

Security measures during maintenance and repairs......................................................... 7

1.2.7

Work on the electrical equipment ...................................................................................... 8

1.2.8

Work on pneumatic equipment..........................................................................................8

1.2.9

Observe environmental regulations................................................................................... 8

2. Description ...............................................................................................................9

2.1 Mechanics ....................................................................................................................................9

2.2 Operator panel............................................................................................................................11

2.3 Plug board ..................................................................................................................................12

2.4 Electronics.................................................................................................................................. 12

3. Labelling.................................................................................................................13

3.1 Threading the Material................................................................................................................ 13

3.1.1 Removing label material ..................................................................................................14

3.1.2

Mounting a new label roll.................................................................................................14

3.1.3

Adjusting the pressure roller............................................................................................16

3.1.4

Lead screw adjustment.................................................................................................... 17

Adjust pressure roller..................................................................................................................18

3.2

Starting labelling.........................................................................................................................18

3.3 Using the FEED key to measure the label pitch.........................................................................19

3.4 Missing label function and web breaks.......................................................................................19

3.5 Control of the labelling................................................................................................................19

3.6 Maintenance............................................................................................................................... 20

4. Connections ...........................................................................................................21

4.1 Output signals.............................................................................................................................21

4.1.1 Error and warning output ................................................................................................. 21

4.1.2

Printer output ...................................................................................................................21

4.1.3

OD-Control output............................................................................................................21

4.1.4

Ready output ...................................................................................................................21

4.1.5

Labelling signals ..............................................................................................................22

4.2

Input signals ............................................................................................................................... 23

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4.2.1 Product sensor.................................................................................................................24

4.2.2

OD Control sensor ...........................................................................................................25

4.2.3

Control signals .................................................................................................................26

4.3

EMI..............................................................................................................................................31

5. Errors and warnings...............................................................................................32

1.1 Dispenser error messages ...........................................................................................................32

1.2 Dispenser warnings......................................................................................................................33

1.3 STO! Power-fail message.............................................................................................................33

6. Technical specification........................................................................................... 34

6.1 Technical Information..................................................................................................................34

6.2 Application specification..............................................................................................................35

6.3 Performance charts.....................................................................................................................35

Operators Manual

ALS 321/421

Release 2/08 Page 3 Important Notes

1. Important Notes

1.1 Overview

The ALS 321/421 is a fully automatic labeller. Operation is very easy and can be learned with a
minimum of training. The machine is controlled by a microprocessor and because of its pro­grammable possibilities it can be used in many applications. Except for cleaning the rolls and
light sensor there is no periodical maintenance necessary. This manual should help you to op­erate the ALS 321/421. For technical questions, especially in the case of a problem, your local
AVERY service organisation will be pleased to help you.

Note: This manual is valid for all ALS 321/431 devices which are equipped with
software version 2.2. Compared to other software versions, there may be differ­ences in operation and functionality.

1.1.1 Manufacturer

This machine was manufactured by:

AVERY Maschinen GmbH

Ohmstrasse 3
85386 Eching

Deutschland

Tel. [phone]

Fax [phone]

1.1.2 Copyright

© 2004 Avery Maschinen GmbH. All rights reserved. No part of this work covered by Avery's
copyright may be reproduced or copied in any form or by any means (graphic, electronic or
mechanical, including photocopying, recording, recording taping, or information and retrieval
systems) without the written permission of Avery Maschinen GmbH. Avery also reserves all
other rights, including the right to make changes or corrections at any time without notice.
Avery make no representation or warranties about the accuracy, currency, completeness or
suitability of the information provided herein and will not be held liable for any use of this infor­mation for any purpose. It is provided "as is" without express or implied warranty.

AVERY and all other related brands and product names are trademarks of Avery Dennison
Corporation. No licence to use or reproduce any of these trademarks or other trademarks of
Avery Dennison Corporation is given or implied. All other brand and product names are the
trademark of their respective owners.

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1.2 Safety

1.2.1 General Safety Notes

In order to avoid any risk of injury due to squeezing between the fixed dispensing edge and the
passing product, it may be necessary to add a protection cover in front of the dispensing edge.
The necessity for this has to be decided on case by case.
See also regulation EN 292 and 294.

1.2.2 Warning Notes in the Text

In this description, two types of notes can be found:

 Warning note – indicates a possible risque of injury for the user. Ignoring the warning can

lead to injuries or material damages.

Example:

CAUTION! - The machine is connected to mains. Only authorised person­nel may open the cover. Operation without this cover is not allowed.

 Special advice regarding the carrying out – please notice!

Example:

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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1.2.3 Operator’s duty of care

The machine was designed and constructed taking into account a
hazard analysis and after careful selection of the harmonised stan­dards to be observed, as well as other technical specifications. Thus,
it corresponds to the state of the art and allows the highest possible
degree of safety during operation.
The safety of the machine, however, can only be put into operating
practice if all measures required for the safety are taken. It falls within
the operator‘s duty of care to plan these measures and to verify their
implementation.
Above all, the operator must make sure that

• the machine is only used in accordance with its purpose (cf. the
section “Use in accordance with the purpose” in the chapter
“Specification”)

• the machine is only operated in faultless serviceable condition
and that especially the safety devices are regularly checked with
respect to their serviceability

• the required personal protective clothing and equipment for oper­ating, maintenance and repair personnel are available and are be­ing used

• a legible and complete copy of the operating instructions is always
available at the place of operation of the machine

• only personnel which is qualified and authorised for it will operate,
service, and repair the machine

• this personnel is instructed in all relevant issues of occupational
safety and environmental protection on a regular basis and is fa­miliar with the operating instructions and especially the safety in­structions contained therein

• all safety and warning instructions on the machine itself are not
removed and are legible

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1.2.4 Concrete security regulations and symbols used

In the following operating instructions, concrete security regulations are indicated in order to
point out the remaining risks which cannot be avoided when operating the machine. These
remaining risks include danger to

• Persons

• Product and machine

• Environment

The symbols used in the operating instructions are above all intended to point out the security
regulations!

This symbol indicates that especially danger to persons has to be
expected.

(Lethal danger, danger of injury)

This symbol indicates that especially danger to the machine, material,
and the environment has to be expected.

The most important aim of the security regulations is to avoid injuries to a person.

• Whenever there is a warning triangle with the caption “Danger” in front of a security regu-
lation, dangers to the machine, materials, and the environment are not excluded.

• Whenever there is a warning triangle with the caption “Warning” in front of a security
regulation, a danger to persons, however, must not be expected.

The symbol used in each case, however, cannot replace the text of the security instruction.
Thus, it is necessary to always read the text completely!

This symbol does not indicate security regulations, but provides in­formation for a better understanding of the machine’s operations.

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1.2.5 Security measures during normal operation

The machine may only be operated by trained and authorised per­sons who are familiar with the operating instructions and are able to
work in accordance with it!

• Before starting the machine, check and make sure that

• only authorised personnel is staying in the operating area of the

machine

• Nobody can get hurt when the machine is started!

• Before every production start-up, the machine must be checked

for visible damage and it must be made sure that it is only oper­ated in faultless working condition! Any defects found must be

immediately reported to the supervisor!
Before every production start-up, all materials/objects that are not
necessary for production must be removed from the operating area of
the machine!
Before every production start-up, it must be checked and made sure
that all safety devices function in a correct manner!

1.2.6 Security measures during maintenance and repairs

Inspection and maintenance periods laid down in the operating in-

structions must be observed!
Observe maintenance and repair instructions in these operating in­structions, which refer to individual components!

Before performing maintenance and repair work, the access to the
operating area of the machine must be prohibited for unauthorised
personnel! Post or put up a sign, which indicates the maintenance, or
repair work!

Before performing maintenance and repair work, turn off the main
switch for the electric power supply and secure it with a padlock!. The
key to this padlock must be in the hands of the person who performs
the maintenance or repair work!
When exchanging heavy machine parts, use only suitable and fault­less load suspension devices and stopping devices!

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1.2.7 Work on the electrical equipment

Repair work on the electrical equipment of the machine may only be
performed by a trained electrician!
Electrical equipment must be checked on a regular basis!
Loose connections must be fixed again!
Exchange damaged lines/cables immediately!
Always keep the switch cabinet closed! Access is only allowed to
authorised personnel with keys/tools!
Never wash down switch cabinets and other housings of electrical
equipment with a water hose for cleaning!

1.2.8 Work on pneumatic equipment

Maintenance and repair work on pneumatic equipment may only be
performed by specially trained personnel!
Before starting maintenance and repair work, depressurise the pneu­matic equipment of the machine!
By way of precautionary maintenance, exchange hose pipes on a
regular basis, even if there is no damage to be detected!
(Observe the manufacturers’ instructions!)
Before setting into operation after maintenance or repair works

• check if loosened screwed connections are tight

• make sure that removed coverings are re-installed

After termination of maintenance and repair work and before re­starting the production, make sure that

• all materials, tools, and other equipment required for maintenance
and repair work are removed from the operating area of the plant

• all safety devices of the plant function in a faultless manner!

1.2.9 Observe environmental regulations

During any and all work on and with the machine, the statutory duties
concerning prevention of waste and the proper waste dis­posal/recycling regulations must be observed.
Especially in the case of installation, repair and maintenance work,
substances which are hazardous for the water, such as detergents
containing dissolvents, may not pollute the soil or get into the sewage
system!
These substances must be stored, transported, collected, and dis­posed of in appropriate containers!

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2. Description

CAUTION! - The machine is connected to mains. Only authorised personnel
may open the cover. Operation without this cover is not allowed.

This chapter explains the structure and the function of the labeller. The expressions used are
explained here.

2.1 Mechanics

The labeller is available in a right-hand or a left-hand version. The expression right or left is
related to the direction of product transport.

The material is unwound from the label roll (3). The maximum diameter of the label roll is 300
mm. The width of the backing paper is 155mm for a 321 and 230mm for a 421 machine. The
label roll is guided by a swing away lever (4).

The dancer arm (011) keeps the material tight and the acceleration forces low. The deviator
roller (8) allows the use of inside or outside wound label web. The deviator roller (9) guides the
material to the dispensing edge. Paper brake brush (6) applies a brake force to the label web
and keeps the label web under a certain tension without disturbing the movement. At the dis­pensing edge (10) the label sensor (15) is mounted. It detects the gap between the labels. The
sensor includes a light source and a light receiver. The software can adjust the sensitivity. With
this information, the machine calculates the position of the label. At the dispensing edge (10)
the label is separated from the backing paper and moved to the product. With a foam roller (16)
in front of the dispensing edge, the label is applied to the product.

The deviator rolls (5) guides the backing material to the drive roller (1).
The drive roller (1) moves the label web according to the adjusted dispensing speed.
The pressure roll (12) has to be positioned in the centre of the label web, in order to guide the

web straight on track. By means of the knurled screws, the pressure roller is held in its required
lateral position on the shaft.

With its handle the pressure roller (12) will be opened and closed. When inserting the material
the pressure roller has to be opened.

The deviator roller (17) guides the backing paper to the rewind mandrel (13). The rewind man­drel should always be set to expanded position when mounting a new roll of labels. This allows
an easy removal of the collected backing material.

To ensure a reliable run of the label web the guides (18) have to be adjusted according to the
width of the labels in use.

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Figure 1 Machine layout

Apart from the drive roller (1), and the material brush (6) the labeller has no mechanical wear­ing parts.

The operator panel (19) is described in the next section of this chapter.

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2.2 Operator panel

The operator panel of the 321/421 is shown in Figure 2, it has 4 digit LED and 6 membrane
keys.

Figure 2 Operator panel

The six membrane keys have the following functions:
FEED: By pressing this key one label will be dispensed. An error or warning indi-

cation may be cleared with this key. Additionally, each time the FEED key
is pressed the machine measures the distance to the next leading label
edge and stores this measurement as the label pitch.

CONTRAST: With this key the contrast value of the label sensor can be adjusted to the

label material in use.
SPEED UP / With these keys the labelling speed can be adjusted
DOWN
POSITION   These keys enable the adjustment of the start delay function, i.e. the posi-

tion of the applied label

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2.3 Plug board

The plug board is shown in Figure 3. Beside the mains switch and the mains cable socket there
are some more holes for optional functions. Standard execution in this machine is one I/O plug
prepared for the product sensor. The connection of the other plugs is described in chapter 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.

Figure 3 Plug board

The fuse holder setting you have to select according to your local main voltage (100, 120, 200
or 230 V). You carry this out by taking off the fuse holder and position the fuse holder insert
accordingly.

2.4 Electronics

As standard the complete electronic is integrated in the machine. For special requirements (wa­ter protection e.g.) a machine version the electronic is housed in a separate cabinet is avail­able.

Product sensor

APSF-Sensor

Applicator

SPS control

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3. Labelling

In this chapter you will learn how to install and adjust the labeller. After this step has been com­pleted, you will be ready to learn how the labeller's parameters can be adjusted to suit your
particular production requirements.

3.1 Threading the Material

Before threading the new material, any old rewound backing material should be removed. Pull
the cone at roller and take the waste paper from the roll. Open the pressure roller and mount
the new label roll. Figure 4 shows the threading for the right hand and the left hand version.

Left hand version Right hand version

Figure 4 Threading diagram

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3.1.1 Removing label material

Before you mount a new roll of labels, it is necessary to remove the accumulated roll of backing
material. Turn the lever the expanding pads retract. The roll of backing material can easily be
pulled off the rewind mandrel.

Figure 5 Removing label material

To ensure a reliable function of the unwind, it is important to exchange the collected backing
material each time you mount a new label roll.

3.1.2 Mounting a new label roll

Mounting of the new label roll depends on the used machine

Unwind Unit ALS 321 Euro

Mount the new label roll to the unwind mandrel and secure the position by means of the unwind
clamp. You achieve a reliable position of the unwind clamp by pressing it firmly against the la­bel roll core, while you are moving the lever 2 to the locking position.

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Figure 6 Unwind Unit at the ALS 321 Euro

Unwind Unit ALS 321/421

By means of the knurled screw the collapsible key can be moved further in or out for clamping
and releasing the label roll.

Figure 7 Unwind Unit at the ALS 321/421

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. Mount the label web through the label sensor. Remove the labels until about 50 cm of the
backing material is exposed. Thread this backing material around the drive and deviator roller.
Fold the end of the backing material back approximately 15 mm and insert the leading edge
into the slot of the rewind mandrel. Turn the lever, the rewind expands, the slot is closed and
the backing material is clamped in the slot. Wind the mandrel a few times to take up any back­ing material slack between the deviator roller and the rewind mandrel.

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Figure 8 Rewind

3.1.3 Adjusting the pressure roller

The pressure roller should always be positioned over the middle of the backing material. This
ensures accurate label placement. Turn the pressure roller away from the drive roller. Loosen
both knurled screws. Move the entire unit to its correct position. Fasten the screws securely
again.

Figure 9 Pressure roller

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3.1.4 Lead screw adjustment

For adjustments of the dispensing edge towards or away from the conveyor, the lead screw
integrated in the labelling head should be used. Positions can be read from the scale on the
dispensing edge bars.

Adjustment of the dispensing edge

Loosen handle 1 and 2 and turn lead screw Z. Once the adjustment is completed pull the han­dles tight again.

Figure 10 Dispensing edge

Printer adjustment

If your labeller is equipped with a printer, you adjust the print position as well with the lead
screw Z. In this case loosen handle (orange) for printer and handle 1. Once the adjustment is
completed, pull the handles tight again.

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Adjust pressure roller

Depending on the application the foam roller has to be adjusted. Loose the both screws and
tighten the screws again after the adjustment was done.

Figure 11 Adjust pressure roller

3.2 Starting labelling

For the labelling operation, four adjustments are necessary:

1. The contrast value for detecting the gap between the labels has to be adjusted. By pressing
the contrast key the value changes between 0 and 255. In the display the status of the La­bel sensor is shown:
G = Gap between the labels. The lamp on the Wenglor label sensor is off.
M = Material in the sensor. The lamp is switched on.
To adjust the contrast of the label sensor do the following steps:

 Put the label web with a label in the sensor fork. If a printed label is used, select the most

transparent part of the label. This is most the lightest part. A “M” has to be shown in the dis­play. If this is not the case, press the contrast key until the “M” appears.

 Press the contrast key until the display change from “M” to “G”. Note the shown value.
 Put the backing paper without label under the label sensor. If there are water signs in the

backing paper put the most transparent location in the sensor fork.

 Press the contrast key until the display change from “G” to “M”.
 Now enter a contrast value in the middle of both measured values.
 Is the difference between both values greater than 40 the adjustment is not critical. Is the

difference lower than the adjustment has to be done more carefully.

 By pressing the feed key the setting can be checked. Only one label should be dispensed

and the label should be stop every time at the same position.

The contrast adjustment is only required and possible for the Wenglor label sensor. With
other sensors, the adjustment is done at the sensor. The indicator in the display can be
used for the adjustment.

2. The position of the label at the dispensing edge has to be adjusted by moving the label sen­sor inside the slot of the dispensing edge.

3. The labelling speed must be adjusted by pressing the keys Speed up or Speed down.

4. The position of the label on the product is defined by 2 factors:

 Position of the product sensor on your conveyor (basic mechanical adjustment)
 Start delay value entered by means of the 2 position keys

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 The value will be increased. The label is positioned nearer the leading edge of the

product.

 The value will be lower. The label is position nearer the end of the product.

3.3 Using the FEED key to measure the label pitch

Each time the FEED key is used to feed the label web the machine measures the distance to
the next leading label edge and stores this measurement internally as the label pitch. The label
pitch is the distance from one leading label edge to the next leading label edge.

The internally stored value for the label pitch is used:

 to stop the label web in the correct position
 for the missing label function which stops the label web in the correct position even if a label

is missing from the label web.

When changing label rolls it is therefore necessary to press the FEED key twice so that the
machine can store the new label pitch. The first press of the FEED key will move the next lead­ing label edge under the gap sensor, the second press will move the web by one full label pitch
and the correct label pitch value will then be stored.

The internally stored label pitch is retained when the machine is turned off.

3.4 Missing label function and web breaks

The missing label function stops the label web in the correct position even when a label is miss­ing from the label web. If there are more than 3 missing labels from the web then the machine
will stop and give the error message E__1.
If the label web has broken or come to an end then the machine will no longer be able to find
the next leading label edge and so after more than 3 signals from the product sensor the error
message E__1 will also be generated.

3.5 Control of the labelling

The machine carries out the labelling of your products fully automatically. Check now and then:

 if there is still enough labelling material on the unwind roll
 if an error has been displayed and the labeller no longer carries out labelling
 if the labels are being placed accurately onto the products. Changes of the label position

can be made with the 2 position keys.

Operating is simpler if you use the optional OD-control, which checks the diameter of the mate­rial roll and triggers an error message when there are not enough labels on the roll anymore. If
the error output is connected to an alarm indicator, an optic or acoustic signal can be gener­ated.

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3.6 Maintenance

The machine can be easily maintained and has only a few wear parts. If you change any mate­rial, note if any glue or waste labels are stuck on the rolls or dispensing edge.

In this case, you have to clean the respective parts. The machine has to be cleaned at least
once a week. Glue and waste labels have to be removed from the rolls, the dispensing edge
and the material brush.

All rollers have to be cleaned from any grease. We will supply a special cleaning set for this.
The material label sensor has to be cleaned from dust regularly. The material brush should be
turned around whenever the material is changed. Any glue has to be removed from the brush.
If there is a soft roll at the dispensing edge for applying the label to the product, check if the
roller is damaged or dirty. Replace if necessary.

The unwind has to operate in such a way, that the dancer arm does not bounce to its end posi­tion. If this is not the case, the friction mechanism should be checked.

If the backing paper is not wound up accurately, the belts have to be tightened.

CAUTION! - Check the electrical connections, especially the mains cable,
for any unreliable connection.

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4. Connections

This machine has a number of inputs to connect sensor’s and a control. Outputs are available
for applicators, a printer and other purposes.

4.1 Output signals

This machine has eight outputs, which switch the output from open circuit to + 24V. The maxi­mum current must not exceed 500 mA. The four signals for error messages, machine ready,
low material and warnings are available for other machines in the process or additional alarm
signals. For connecting an applicator three signals are available and one additional for the prin­ter.
The output signals are available at terminal connector CN33 on the main board. The wiring of
the terminal is shown otherwise.

4.1.1 Error and warning output

The outputs for errors and warnings are available on the terminal CN33 and optional on the I/O
plug. The signals are switched active (+24V) if an error or warning occurs. When the error or
warning is erased, the signal becomes passive again.

4.1.2 Printer output

This machine can be connected to a printer. To use the printer the PDT parameter should be
adjusted.
A new label cannot be dispensed until the printer dwell time set in PDT is over.

4.1.3 OD-Control output

This output is switched active (+24V) if the OD-Control input is switched active during dispens­ing.

4.1.4 Ready output

This output shows when the machine is ready for labelling. This output is switched inactive if
there is:

 an error message appears in the display
 the mains supply voltage has fallen below specification
 the machine is in the extended or configuration menus
 the machine requires initialisation
 in OFF condition.

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4.1.5 Labelling signals

For direct dispensing the airstream signal can be used to control a pneumatic driven dispensing
edge.

Product start

Dispense

Motor run
signal

POS

Product start

PRDL

APOS

Suppression

Ready

Label start

POS

POS

1

2

4

3

ASTP APOS ASTP

Suppression

1
2
3

Missing Label: New start of dispense during dispenser activ
Inhibit activ
Machine not ready. Errorcondition or not online

4

Productstart disabled. PRDL activ

Figure 12 Timing diagram

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4.2 Input signals

This machine (dispenser) is provided with photo coupled inputs for:

 the product sensor signal
 an inhibit signal for inhibiting labelling
 a signal from an OD control which shows the end of the material roll.

The inputs are galvanically separated through photo couplers to connect to PNP or NPN out­puts. The wiring and the connection of the signal plug is shown otherwise. The input voltage
across the inputs must be in the range of 15 V to 30 V to switch active.

ln+

Signal

ln-

Machine

Bridge

Bridge

(alternative switch)

+24V DC

NPN

Opto­isolator

2K2

ln+

Signal

ln-

Machine

(alternative switch)

+24V DC

PNP

Opto­isolator

2K2

Figure 13 Input connection and input circuit

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4.2.1 Product sensor

The product sensor starts the labelling. The source of the signal could be a optical sensor, a
switch or a signal from a PLC. The time between start signal and start of dispensing (adjusted
with POS) should be as small as possible. This means that an optical sensor should be placed
10 to 20 mm before the dispensing edge. The minimum distance is necessary for the internal
speed compensation.

The machine is supplied as standard with one socket for connecting the product sensor. You
may either use a NPN or PNP type sensor output.

+24V

GND

13

black

blue

white

red

brown

5
9
4
8
3
7
2
6
1

Signal-

GND

Signal+

Supply

white

black

blue

26

34

27

CN33S5-5-C8-30

NPN-Sensor

5
9
4
8
3
7
2
6
1

Figure 14 Example for connecting an NPN sensor (Datalogic)

+24V

GND

13

black

blue

white

red

brown

5
9
4
8
3
7
2
6
1

Signal-

GND

Signal+

Supply

white

black

blue

26

34

27

CN33S5-5-C8-30

PNP-Sensor

5
9
4
8
3
7
2
6
1

Figure 15 Example for connecting an PNP sensor (Datalogic)

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4.2.2 OD Control sensor

Optional an OD control could be mounted to control the label roll. If the label material is nearly
empty the sensor gives an signal. A warning message and an output signal inform the personal
that in the next time the material has to be changed.

+24V

GND

14

black

green

white
red

brown

5
9
4
8
3
7
2
6
1

Signal-

GND

Signal+

Supply

white

grey

blue

25

11
27

CN33E3JK-R2M2

NPN sensor

5
9
4
8
3
7
2
6
1

Figure 16 NPN connection of optional ODC sensor

+24V

GND

14

black

green

white
red

brown

5
9
4
8
3
7
2
6
1

Signal-

GND

Signal+

Supply

white

grey

blue

25

11
27

CN33E3JK-R2M2

NPN sensor

5
9
4
8
3
7
2
6
1

Figure 17 PNP connection of optional ODC sensor

Operators Manual

ALS 321/421

Release 2/08 Page 26 Connections

4.2.3 Control signals

An optional connector could be installed for integration of the machine in the line control.

5
9
4
8
3
7
2
6
1

5
9
4
8
3
7
2
6
1

CN33

red

green

black schwarz

rot

grün

+24 Vo lt +24 Vo lt

Ground Masse

Warning output Warnausgang

Error output Fehlerausgang

Inhi b it - Startunterdrückung -

Inhi b it + Startunterdrückung +

white weiß
blue blau

yellow gelb

21
27
7
20

19

14

brown

orange
violet

braun

orange
lila

TBD
TBD

31

Ready output Betriebsbereitschaft

Figure 18 Optional connector for process control

Operators Manual

ALS 321/421

Release 2/08 Page 27 Connections

Figure 19 Internal I/O connector

Operators Manual

ALS 321/421

Release 2/08 Page 28 Connections

Figure 20 Wiring diagram

Operators Manual

ALS 321/421

Release 2/08 Page 29 Connections

Figure 21 Layout dispenser electronic board

Operators Manual

ALS 321/421

Release 2/08 Page 30 Connections

LED Voltage

Ready LED

Overtemperature 100% on
Short circuit 25% on / 75% off
Both 75% on / 25% off

+ Direction

- Direction

- NC

+ NC

- Clock

Ready Collector
Ready Emitter

48VAC

48VAC

Phase1B

Phase1A

800

400

Resolution

Figure 22 Layout stepper motor driver

The jumper position has to be 800 steps.

Figure 23 Layout display unit

Operators Manual

ALS 321/421

Release 2/08 Page 31 Connections

4.3 EMI

To protect the machines against electrical noise and to protect production of electrical noise
you have to follow this rules:

Rule 1

All metallic parts must have a good and plane contact (no lacquer, aluminium oxide is an isola­tor). Use scratch washers.

Rule 2

Signal lines (Data- , communication- and control cable) has to separated to power cables. The
minimum distance is 50 cm (20 cm inside a cabinet).

Rule 3

All signal lines should be lead in the machine or cabinet only on one side.

Rule 4

Unshielded cables must be twisted (both poles).

Rule 5

On all inductive components (relays, valves) must be directly connected a clamp circuit (diode,
MOV).

Rule 6

All signal lines must be shielded. The shield must have a good earth connection on both

sides.
For the connection use metallic clamps. Don’t use a soldered wire for this connection.
In case of different earth potential on both cable sides install parallel a cable of at minimum 10
mm

2

.

Rule 7

The shield of analogue cable (Video etc) should be shielded only on one side. Normally there is
no such cable with labelling machines.

Rule 8

Line filter has to be mounted directly on the cable entry.

Rule 9

Cables should not fly in the air. Lead all cables nearby metallic, grounded parts. Ground un­used cables and wires in a cable at minimum on one side, better on both.

Rule 10

Cables should not be longer as necessary.

Operators Manual

ALS 321/421

Release 2/08 Page 32 Errors and warnings

5. Errors and warnings

The software continuously checks during the labelling, whether normal operation is possible. If
labelling is not possible, the display shows a message e.g. E_XX. If labelling can be continued,
although a problem has been recognised, the display shows a warning e.g. W_XX. By pressing
the key FEED the message will be erased.
Error and warning signals are available at the outputs and may be used for external purposes.
If an error cannot be erased, please call your local AVERY service technician.

1.1 Dispenser error messages

In case of an error message the relevant output is switched. The signal can be used for inter­connection with an external machine control.

Message Meaning How to solve

E__0 Pressure roller is open Close the pressure roll and make a new

initialisation if necessary

E__1 During material transport no label

is recognised over a length of 4
labels

Insert new material and check the label
sensor

E__4 Check sum of the labelling data is

wrong. Labelling Parameters are
set to the factory adjustment.

All labelling parameter have to be ad­justed again

E__5 10V supply voltage for label sen-

sor low.

Short circuit in label sensor or cable.
Voltage regulator U14 is damaged.

E__6 24V Voltage low Short circuit on an output. Total load too

high i.e. max is 3A for all outputs.
Voltage regulator U1 is damaged. Chan­ge main board.

E__7 Missing label on product One or several product could not be la-

belled. Distance between products too
close. Increase speed of printer.

E__8 Error stepper motor driver The stepper motor control has detected

an error. The fault is indicated by the
LED’s on the driver.

E__9 10V supply for label sensor too

high

Voltage regulator U14 damaged

E__10 24V supply too high Voltage regulator U1 damaged
___0 Process error (Divide overflow) Hardware failure external noise. EPROM

damaged. Turn off power and on again.
Change EPROM or main board

Operators Manual

ALS 321/421

Release 2/08 Page 33 Errors and warnings

Message Meaning How to solve

___1 Illegal interrupt (processing error) Hardware failure external noise. EPROM

damaged. Turn off power and on again.
Change EPROM or main board

___2 Illegal bank interrupt (processing

error)

Hardware failure external noise. EPROM
damaged. Turn off power and on again.
Change EPROM or main board

INTO Illegal interrupt INTP0 (processing

error)

Hardware failure external noise. EPROM
damaged. Turn off power and on again.
Change EPROM or main board.

1.2 Dispenser warnings

In case of a warning message the relevant output is switched. The signal can be used for inter­connection with an external machine control. Warning W__5 activates only the special OD warn
output.

Message Meaning How to solve

W__2

Error while writing in the
EEPROM

EEPROM defect, Start ma­chine again, if problem remains
the same, exchange EEPROM
as soon as possible

W__5

Material end by the OD con­trol recognised

Insert a new material roll

W__6

Too many products between
sensor and dispensing edge

Move the sensor closer to the
dispensing edge

1.3 STO! Power-fail message

The message STO! appears in the display as the machine is switched off or if the mains supply
voltage has fallen below specification.
The message STO! (store) indicates that the machine has stored some parameters internally
as a power fail condition was detected. The error output is switched active and the ready output
inactive simultaneously with STO! appearing in the display.
If the mains supply voltage only experiences a drop in level and then returns to a correct level
then the ready output is restored to its previous condition but the message STO! will remain in
the display to indicate that there has been a problem with the mains supply.

Operators Manual

ALS 321/421

Release 2/08 Page 34 Technical specification

6. Technical specification

The following data are maximum values. Depending on label material, operation environment
and labelling condition the real value could be lower.

6.1 Technical Information

Description ALS 321 ALS 421

Label width:
incl. Backing paper

10 mm ... 155 mm 10 mm ... 230 mm

Label length 10 - 220 mm
Diameter label roll max. 300 mm
Core diameter label roll 37 mm
Labelling speed 2 - 30 m/min 2 - 18 m/min
Material transport 0,1 mm per motor step
Accuracy at dispensing

edge

± 0,5mm

Labelling rate

see performance charts
Rewind collapsible
Dispensing edge L- shape, fixed
Versions available Left and right hand
Dimensions (w, h, d) 560 * 630 * 340 mm 560 * 630 * 410 mm
Weight 28 kg 35 kg
Display panel 4 digit LED display, 6 membrane keys
Label sensor Infrared sensor, automatic adjustment possible
Certification Confirms all relevant actual European standards
Protection class IP 41, IP54 on request
Operating environment 5 – 40°C, storage 0 – 70°C; 30 - 80%, non condensing
Power consumption 300 VA
Mains voltage 100V~, 115V~, 200V~ and 230V~ 50/60Hz (6.3A for 110V else

3.15A), +5%- 10%

Operators Manual

ALS 321/421

Release 2/08 Page 35 Technical specification

6.2 Application specification

The labeller is designed and built for automatic applies of self-adhesive labels.

6.3 Performance charts

The following charts show the maximal theoretically labels per minute rate. Tolerances in prod­uct speed, label and product dimensions reduce the label rate. The charts are valid for direct
dispensing (without applicator and printer). For critical applications, performance test should be
done first. The charts are valid for software version V3.0.

0 5 10 15 20 25 30 m/min

labels/min

0

100

200

300

400

500

600

700 25 mm

50 mm
75 mm
100 mm
150 mm
250 mm

Figure 24 Performance

Operators Manual

ALS 321/421

Release 2/08 Page 36 Technical specification

0 5 10 15 20 25 30 m/min

mm

0

1

2

3

4

5

6

7

8

9

Figure 25 Acceleration

0 5 10 15 20 25 30 m/min

mm

0

1

2

3

4

5

6

7

8

9

10

Figure 26 Stop delay