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
Operators Manual
ALS 321/421
Release 2/08 Page 2 Important Notes
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. +49-(0)8165-925-0
Fax +49-(0)8165-3143
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.
Operators Manual
ALS 321/421
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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.
Operators Manual
ALS 321/421
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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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ALS 321/421
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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.
Operators Manual
ALS 321/421
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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!
Operators Manual
ALS 321/421
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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!
Operators Manual
ALS 321/421
Release 2/08 Page 9 Description
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.
Operators Manual
ALS 321/421
Release 2/08 Page 10 Description
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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