Discontinued
S
pare parts available until 12/201
4
ALS
350
450
USER MANUAL
Label Dispenser
Article number: A6432, Release 02/2009
3
CONTENTS
ALS
350
450
1 Please observe the following
1.1 General information. . . . . . . . . . . . . . 6
1.1.1 Validity and applicability of this manual . . . . . 6
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical State. . . . . . . . . . . . . . . . . . . . . . . . 6
Copyright notice . . . . . . . . . . . . . . . . . . . . . . . 6
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.2 Conventions and information . . . . . . . . . . . . . 7
Explanation of symbols. . . . . . . . . . . . . . . . . . 7
Warnings concerning dangers and risks. . . . . 7
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Supplemental information. . . . . . . . . . . . . . . . 7
Directional information . . . . . . . . . . . . . . . . . . 8
ALS 350 and ALS 450 . . . . . . . . . . . . . . . . . . 8
1.2 Safety instructions . . . . . . . . . . . . . . . 9
1.2.1 Information and qualifications. . . . . . . . . . . . . 9
Pay attention to the information . . . . . . . . . . . 9
Information must be made available. . . . . . . . 9
Ensure necessary qualifications . . . . . . . . . . . 9
1.2.2 Machine operating safety . . . . . . . . . . . . . . . 10
Appropriate use. . . . . . . . . . . . . . . . . . . . . . . 10
Protect against injuries that can result from
electrical current . . . . . . . . . . . . . . . . . . . . . . 10
Protect against injuries that can result from
mechanical actions . . . . . . . . . . . . . . . . . . . . 10
Protection against chemical injuries . . . . . . . 10
1.2.3 Before every production start . . . . . . . . . . . . 11
Operator's obligation and service personal to
exercise care. . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating personnels' obligation to exercise
care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Equipment description
2.1 Overview of the ALS 350. . . . . . . . . 12
2.1.1 Structural elements. . . . . . . . . . . . . . . . . . . . 12
2.1.2 Principle of operation . . . . . . . . . . . . . . . . . . 14
2.1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . 16
Characteristic values. . . . . . . . . . . . . . . . . . . 16
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ambient conditions . . . . . . . . . . . . . . . . . . . . 16
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 16
Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical system. . . . . . . . . . . . . . . . . . . . . . 16
Control system . . . . . . . . . . . . . . . . . . . . . . . 16
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 17
Right-hand version. . . . . . . . . . . . . . . . . . . . 17
Left-hand version . . . . . . . . . . . . . . . . . . . . . 17
2.2 Overview of the ALS 450 . . . . . . . . . 18
2.2.1 Structural elements . . . . . . . . . . . . . . . . . . . 18
2.2.2 Principle of operation . . . . . . . . . . . . . . . . . . 20
2.2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . 22
Characteristic values . . . . . . . . . . . . . . . . . . 22
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ambient conditions. . . . . . . . . . . . . . . . . . . . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 22
Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical system . . . . . . . . . . . . . . . . . . . . . 22
Control system. . . . . . . . . . . . . . . . . . . . . . . 22
Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 23
Right-hand version. . . . . . . . . . . . . . . . . . . . 23
Left-hand version . . . . . . . . . . . . . . . . . . . . . 23
2.3 Options. . . . . . . . . . . . . . . . . . . . . . . 24
Serial interface. . . . . . . . . . . . . . . . . . . . . . . 24
Roll diameter control . . . . . . . . . . . . . . . . . . 24
Adjustable dispensing edge. . . . . . . . . . . . . 24
Spring-loaded dispensing edge . . . . . . . . . . 24
Pneumatic dispensing edge. . . . . . . . . . . . . 24
Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Water-resistant electronic control unit . . . . . 24
2.4 Operator controls . . . . . . . . . . . . . . . 25
2.4.1 Operator panel. . . . . . . . . . . . . . . . . . . . . . . 25
LED indicator . . . . . . . . . . . . . . . . . . . . . . . . 25
Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4.2 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Control system . . . . . . . . . . . . . . . . . 27
2.5.1 Brief description . . . . . . . . . . . . . . . . . . . . . . 27
2.5.2 Menus for operators and calibration
technicians. . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5.3 Monitoring functions. . . . . . . . . . . . . . . . . . . 29
Dispensing a label to each product . . . . . . . 29
Label supply. . . . . . . . . . . . . . . . . . . . . . . . . 29
If errors occur. . . . . . . . . . . . . . . . . . . . . . . . 29
4
CONTENTS
ALS
350
450
3 Prior to operating
3.1 Insert the labelling material –
ALS 350. . . . . . . . . . . . . . . . . . . . . . 30
3.1.1 Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Insert the label roller . . . . . . . . . . . . . . . . . . . 30
Remove the old backing material . . . . . . . . . 30
Remove adhesive residues. . . . . . . . . . . . . . 30
Insert new label roll. . . . . . . . . . . . . . . . . . . . 31
3.1.3 Threading the label ribbon . . . . . . . . . . . . . . 32
Overview of the threading path diagram. . . . 32
Thread the label ribbon at the unwind unit . . 33
Guide the label ribbon around the dispensing
edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Thread the label ribbon at the rewind unit. . . 35
3.2 Insert the labelling material –
ALS 450. . . . . . . . . . . . . . . . . . . . . . 36
3.2.1 Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2.2 Insert the label roller . . . . . . . . . . . . . . . . . . . 36
Remove the old backing material . . . . . . . . . 36
Remove adhesive residues. . . . . . . . . . . . . . 36
Insert new label roll. . . . . . . . . . . . . . . . . . . . 37
3.2.3 Threading the label ribbon . . . . . . . . . . . . . . 38
Overview of the threading path diagram. . . . 38
Thread the label ribbon at the unwind unit . . 39
Guide the label ribbon around the dispensing
edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Thread the label ribbon at the rewind unit. . . 41
3.3 Mechanical settings. . . . . . . . . . . . . 42
3.3.1 Setting the ribbon guides . . . . . . . . . . . . . . . 42
Operator panel support. . . . . . . . . . . . . . . . . 42
Setting the ribbon guides on the dispenser
head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Deflection roller on the rewind unit . . . . . . . . 42
3.3.2 Adjust pressure roller at the dispensing edge43
3.3.3 Adjust the pressure roller and the braking
brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pressure roller. . . . . . . . . . . . . . . . . . . . . . . . 44
Braking brush . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.4 Adjust (optional) the position of the dispensing
edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Adjusting vertically . . . . . . . . . . . . . . . . . . . . 45
4 Operation
4.1 Activation and shut-down. . . . . . . . . 46
4.1.1 Starting the machine . . . . . . . . . . . . . . . . . . 46
Automatic material initialisation . . . . . . . . . . 46
Manually initialise the material. . . . . . . . . . . 47
4.1.2 Labelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 48
Start dispensing labels. . . . . . . . . . . . . . . . . 49
Unwind unit . . . . . . . . . . . . . . . . . . . . . . . . . 50
Rewind unit . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1.3 Stop/end the label dispensing . . . . . . . . . . . 50
4.1.4 Tandem operation . . . . . . . . . . . . . . . . . . . . 51
Principle of operation . . . . . . . . . . . . . . . . . . 51
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 52
Start dispensing labels. . . . . . . . . . . . . . . . . 52
Reloading label material. . . . . . . . . . . . . . . . 53
Switching off. . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2 Setting and monitoring . . . . . . . . . . . 55
4.2.1 Settings in the standardmenu . . . . . . . . . . . 55
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Calling up menu. . . . . . . . . . . . . . . . . . . . . . 55
Call up function . . . . . . . . . . . . . . . . . . . . . . 55
4.2.2 Label stop position (STOD) . . . . . . . . . . . . . 56
4.2.3 Dispensing speed (VELO) . . . . . . . . . . . . . . 57
Automatic dispensing speed (optional) . . . . 57
4.2.4 Label position on the product (POS) . . . . . . 58
4.2.5 Automatic material initialisation (INIT) . . . . . 59
4.2.6 If errors occur. . . . . . . . . . . . . . . . . . . . . . . . 60
Warning messages . . . . . . . . . . . . . . . . . . . 60
Error messages . . . . . . . . . . . . . . . . . . . . . . 60
4.3 Product databanks . . . . . . . . . . . . . . 61
4.3.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3.2 Loading product data banks. . . . . . . . . . . . . 61
Please observe: . . . . . . . . . . . . . . . . . . . . . . 61
Activating product databanks at switch-on. . 62
Activating product databanks after
switch-on . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3.3 Create/save product databank . . . . . . . . . . 63
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 63
Saving the product databank . . . . . . . . . . . . 63
Documenting product databanks . . . . . . . . . 63
4.3.4 Delete the product databank . . . . . . . . . . . . 64
5
CONTENTS
ALS
350
450
4.4 Settings in the extended menu . . . . 65
4.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.2 Activating an extended menu . . . . . . . . . . . . 67
Please observe: . . . . . . . . . . . . . . . . . . . . . . 67
Calling up menu . . . . . . . . . . . . . . . . . . . . . . 67
Call up function. . . . . . . . . . . . . . . . . . . . . . . 67
Exit the extended menu . . . . . . . . . . . . . . . . 67
4.4.3 Position of second label (POS2). . . . . . . . . . 68
4.4.4 Position of third label (POS3) . . . . . . . . . . . . 68
4.4.5 Speed ratio (VERT). . . . . . . . . . . . . . . . . . . . 69
4.4.6 Adjust the label stop sensor (CONT) . . . . . . 70
Technology . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Automatically adjusting the photoelectric
sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Manually adjusting the sensor . . . . . . . . . . . 71
4.4.7 Label distance (LPIT) . . . . . . . . . . . . . . . . . . 72
Set distance . . . . . . . . . . . . . . . . . . . . . . . . . 72
Check setting . . . . . . . . . . . . . . . . . . . . . . . . 72
4.4.8 Distance from the label stop sensor to the dis-
pensing edge(E–SS). . . . . . . . . . . . . . . . . . . 73
Set distance . . . . . . . . . . . . . . . . . . . . . . . . . 73
Check setting . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4.9 Product length (PRDL) . . . . . . . . . . . . . . . . . 75
4.4.10 Polarity of the product sensor (P_S_). . . . . . 76
4.4.11 Polarity of the label stop sensor (S_S_) . . . . 76
4.4.12 Number of unlabelled products (MLAB) . . . . 77
4.4.13 Electronic transmission ratio of the RPM trans-
mitter (EGRA) . . . . . . . . . . . . . . . . . . . . . . . . 77
4.4.14 Advance print start (PDT) . . . . . . . . . . . . . . . 78
4.4.15 Printer dwell time (PDWT) . . . . . . . . . . . . . . 78
4.4.16 Tandem operation (TMOD). . . . . . . . . . . . . . 79
4.4.17 Applicator type (APPL) . . . . . . . . . . . . . . . . . 79
4.4.18 EP cylinder dwell time (APT1) . . . . . . . . . . . 79
4.4.19 Blowing time (APT2). . . . . . . . . . . . . . . . . . . 79
4.4.20 Delay time (APT3). . . . . . . . . . . . . . . . . . . . . 79
4.4.21 Fine tuning of the dwell time (APT4). . . . . . . 79
4.4.22 Delete a product data bank (LOAD) . . . . . . . 79
4.4.23 Create / save product data bank (SAVE). . . . 79
4.4.24 Delete a product data bank (DEL) . . . . . . . . 79
4.5 Automatic dispensing speed (APSF) 80
4.5.1 Principle of operation . . . . . . . . . . . . . . . . . . 80
4.5.2 Electronic transmission ratio of the RPM trans-
mitter (EGRA). . . . . . . . . . . . . . . . . . . . . . . . 81
Setting the compensation factor. . . . . . . . . . 81
Test the setting. . . . . . . . . . . . . . . . . . . . . . . 81
4.6 Applicator (optional) . . . . . . . . . . . . . 82
4.6.1 Principle of operation . . . . . . . . . . . . . . . . . . 82
4.6.2 Functions in the extended menu . . . . . . . . . 83
Please observe the following: . . . . . . . . . . . 83
Calling up the extended menu. . . . . . . . . . . 83
Applicator type (APPL). . . . . . . . . . . . . . . . . 83
EP cylinder dwell time (APT1) . . . . . . . . . . . 84
Blowing time (APT2) . . . . . . . . . . . . . . . . . . 84
Delay time (APT3) . . . . . . . . . . . . . . . . . . . . 84
Fine tuning of the dwell time (APT4) . . . . . . 85
5 After operation
5.1 Care and cleaning . . . . . . . . . . . . . . 86
5.1.1 Cleaning agents. . . . . . . . . . . . . . . . . . . . . . 86
5.1.2 Regular maintenance. . . . . . . . . . . . . . . . . . 86
Remove paper waste. . . . . . . . . . . . . . . . . . 87
Braking brush. . . . . . . . . . . . . . . . . . . . . . . . 87
Capacitive sensor at the dispenser head. . . 88
6 Operational malfunctions
6.1 Warning messages. . . . . . . . . . . . . . 89
6.1.1 Please observe: . . . . . . . . . . . . . . . . . . . . . . 89
6.1.2 If a problem occurs. . . . . . . . . . . . . . . . . . . . 89
6.1.3 Warning messages . . . . . . . . . . . . . . . . . . . 89
6.2 Error messages . . . . . . . . . . . . . . . . 91
6.2.1 If a malfunction occurs. . . . . . . . . . . . . . . . . 91
6.2.2 Error codes. . . . . . . . . . . . . . . . . . . . . . . . . . 91
7 Appendix
7.1 Factory settings . . . . . . . . . . . . . . . . 95
7.2 Product databanks . . . . . . . . . . . . . . 97
7.3 EC Declaration of Conformity. . . . . . 99
6
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
350
450
1.1.1 Validity and applicability of this manual
Contents
The present manual refers exclusively to the ALS 350
and ALS 450 labeller machines. The manual is to be
referred to for correct operation and adju stm e nt of the
machine.
The prerequisites for operation and adjustment are
proper installation and configuration of the machine.
For technical questions which are not addressed in this
operating manual:
£ Observe the instructions contained in the labeller
service guide
or
£ Request assistance from a service technician at our
sales partner.
– The customer service at ou r sales partner is at your
disposal and particularly helpful with configuration
settings and remedying malfunctions.
Technical State
Technical state as of: 02/2009
Software version: 7.2
Avery Dennison reserves the right to:
– implement modifications of structural parts, compo-
nents and software as well as to use equivalent
components that keep pace with the current state of
technology in lieu of the specified components.
– change information contained in this manual.
An obligation to extend these modifications to previously
delivered machines is excluded.
Copyright notice
All rights to this operating manual are assigned to Avery
Dennison. Transmission, reprinting or any other means
of reproduction of this manual, whether whole or in part,
are not allowed without prior written permission. Third
parties, in particular competitors, are not to be allowed
access to information derived from this manual.
Printed in Germany
Manufacturer
Avery Dennison Deutschland GmbH
Ohmstraße 3
D–85386 Eching
Phone: +49-8165-925-0
Fax: +49-8165-3143
http://www.machines.averydennison.com
1 PLEAS E OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
7
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
350
450
1.1.2 Conventions and information
Explanation of symbols
In order to facilitate legibility and an overview, the various types of information used herein are categorised
and identified with certain symbols.
Sentences that are introduced by an arrow contain procedural instructions.
£ Carry out procedural instructions one after the other
in the prescribed order.
The following information is introduced with a dash:
– List items
– Descriptions of conditions
– Description of previous work steps
– Prerequisites for implementing a ctions described in
the following passage
Warnings concerning dangers and risks
Important text passages which must absolutely be followed are particularly marked for special attention:
DANGER!
A danger notice indicates an imminent
hazardous situation which, if not avoided,
could result in death or serious injury of the
personnel!
The notice contains instructions on how to
avoid or prevent the danger(s).
£ The instructions must be followed.
WARNING!
A warning notice indicates risks which could
result in death or serious injury of the
personnel! The notice contains safety
instructions on how to safeguard possibly
affected personnel.
£ The instructions must be followed.
CAUTION!
A caution notice indicates risks which, if
unheeded, could lead to material damage or
bodily injury (minor injuries). The notice
contains instructions on how to prevent
damage or injury.
£ The instructions must be followed.
Illustrations
When required, text passages are accompanied by
illustrations. The reference to an illustration is indicated
by typesetting the [illustration number] in square brackets. Capital letters following an illustration number, e.g.
[12A], refer to the corresponding position indicated in
the illustration.
In general, the right-hand version of labeller ALS 350 is
depicted in the illustrations. The left-hand version or the
ALS 450 are only depicted if differentiation is necessary.
Supplemental information
The "Experts" symbol earmarks activities that
only to be performed by knowledgeable and
trained personnel.
The information symbol indicates notices and
recommendations as well as additional helpful
information.
Operating materials:
– Operating materials, e.g. lubricants or
cleaning agents
8
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
350
450
Directional information
Unless otherwise indicated, the directional information
mentioned in the text refers to the construction of the
right-hand version of Top Labeller. See Figure [1] for
the explanation of directional information.
ALS 350 and ALS 450
The operation of the two labellers described in this
operating manual is very similar. In general, the righthand version of labeller ALS 350 is described. The lefthand version or the ALS 450 are only discussed if the
descriptions deviate significantly.
In the header of each page, it is annotated whether the
respective page applies to the ALS 350 and ALS 450 or
to only one of the two types.
[1] Definition of directional information
A Front
B Rear
C Upward
D Downward
E Left
F Right
G Clockwise
H Counter-clockwise
A
B
C
D
E
F
G
H
9
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
350
450
1.2.1 Information and qualifications
Pay attention to the information
WARNING!
Reliable and safe operation of the labeller is
only guaranteed if all necessary informat ion
is observed!
£ Read this operating manual thoroughly
and observe all notices prior to operation.
£ Observe all additional safety and warning
notices attached to the labeller.
£ Only allow qualified persons to operate
and adjust the labeller.
Information must be made available
This operating manual
£ is to stored at the machine operating location and
made accessible to the operator.
£ is to maintained in legible condition.
£ is to be made available to the new owner if the ma-
chine is sold.
£ Safety and warning notices attached to the machine
must be kept clean and legible. Missing or damaged
warning labels and plates are to be replaced.
Ensure necessary qualifications
£ Only allow the machine to be operated, adjusted
and serviced by instructed and authorised personnel.
£ Adjustment tasks via the expanded menus as well
as programming and administration of product databases are only to be performed by qualified and appropriately trained personnel or the customer
service.
£ The responsibilities for operation, adjustment and
servicing of the machine must be clearly defined
and consistently maintained.
£ Moreover, personnel are to be regularly instructed
about work safety and environmental protection issues.
Operator qualifications
Instruction of the operating personnel must ensure:
– that operating personnel can use the machine inde-
pendently and without posing a danger.
– that operating personnel can remedy minor opera-
tional malfunctions themselves.
£ Train at least 2 person to operate the machine.
£ Make label materials for test purposes available in
sufficient quantities.
Qualifications for adjustment tasks
Settings in the expanded menus of the control
software require knowledge based on experience:
– The adjustment personnel must be familiar
with how the labeller functions.
– Adjustment personnel must be familiar with
the entire system into which the labeller is integrated.
– Adjustment personnel must be able to cor-
rectly apply the functions in the expanded
menu system to appropriately address the
order-specific requirements.
1.2 SAFETY INSTRUCTIONS
10
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
350
450
1.2.2 Machine operating safety
Appropriate use
The labeller is a fully automatic machine for the application of self-adhesive labels to products or packages.
The machine is to be equipped by the operation planners with suitable safety devices so as to protect the
operating personnel from possible endangerment –
e.g. pinching or entrapment of body parts due to reaching between product and dispensing edge.
WARNING!
Improper usage of the machine can lead to
accidents, material damage and loss of production!
£ Only operate this machine in accordance
with information contained in this manual.
£ Do not put the machine into operation
without the required safety equipment in
place.
£ Only make adjustments to the machine in
accordance with this manual and with all
due care.
Protect against injuries that can result
from electrical current
WARNING!
The machine is connected with the mains
supply! Contact with energised components
can result in life-endangering currents
through the body as well as burns.
£ Only put the machine into operation when
installed in a correctly installed housing.
– The housing may only be removed by
trained personnel when the machine is
de-energised.
£ Pull out the mains power connection plug
from the socket before cleaning and
maintenance.
The machine is not protected against
splashing water.
£ Maintain the machine in a dry condition.
£ In case fluids penetrate into the machine
interior, immediately switch off the machine and disconnect or plug out from the
mains power supply. Notify a service
technician.
Protect against injuries that can result
from mechanical actions
WARNING!
Risk of injury due to moving or rapidly rotating parts!
£ The following regulations always apply:
£ Keep a distance from running machines. Wear
snug-fitting clothing and, if necessary, hair nets.
£ Even when the machine is idle, maintain the area
clear of movable parts if the possibility exists that
the machine could start.
£ Never lay tools or loose parts on the machine if the
possibility exists that the machine could start.
£ Switch off the machine before performing mechani-
cal adjustment tasks.
£ Do not wear ties, loose garments, jewellery, watch-
es or similar articles on the body when in the machine vicinity.
CAUTION!
Danger of bodypart trapping and pinching at
the dispensing edge due to products moving
in the conveyor direction!
£ Never reach between the product and dis-
pensing edge of running or operationready machines.
£ During operation, never remove or defeat
the purpose of protective guards that prevent reaching into the machine.
Protection against chemical injuries
CAUTION!
Operational materials such as cleaning
agents or adhesive solvents may pose a
health risk.
£ Rules, work guidelines and safety regula-
tions issued by the manufacturer must
absolutely be followed!
11
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
350
450
1.2.3 Before every production start
Operator's obligation and service personal
to exercise care
£ Ensure the following prerequisites correspond to the
information of the operating manual:
– The machine is correctly installed and appropriately
configured for the requirements.
– All necessary safety equipment is installed.
– The machine has successfully completed at least
one test run.
– The machine is connected to the power supply.
£ The required personal safety gear, e.g . hair ne ts,
must be provided. Make sure that the safety gear is
used in accordance with the regulations.
Operating personnels' obligation to exercise care
£ Verify flawless functioning of the safety equipment.
£ Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
£ Use personal safety gear in accordance with the
regulations, e.g. wear hair nets.
£ Non-required materials and objects are to be re-
moved from the working area of the machine.
£ Make sure that only persons authorised to work on
the machine are within the working area of the machine.
£ Make sure that no one will be placed in a hazardous
situation as a result of the machine startup.
12
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
2.1.1 Structural elements
[2] Right-hand version of the ALS 350 Labeller
H
B
A
D
F
J
I
K
L
O
E
C
N
M
P
G
2 EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
13
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
A Unwind unit
– The unwinding spindle holds the label roll.
B Guiding rod for unwind unit
– Secures the label roll on the unwinding spindle.
C Unwind unit deflection roller
D Drive roller unit of the unwind unit
– Pulls the label ribbon evenly from the label roll and
transports it into the loop space.
E Pressu re rolle r of th e un wind un it
– Presses the label ribbon against the drive roller unit.
F Braking brush
– Allows label ribbon to run smoothly, prevents flutter-
ing.
G Loop space
– Shaft located below the pressure roller and the brak-
ing brush.
– In this area the label ribbon forms a loop.
HCasing
– Houses the control electronics, drive electrical sys-
tem, main switch, and fuses.
– If equipped with optional water-resistant electronic
control unit: the electronic control unit, drive electri-
cal system, and electrical fuses are built into a sep-
arate switch cabinet.
I Mounting brackets
– For securing the machine in the system.
J Operator panel
– Used to enter commands into the machine and to
display operating states and error messages
– If equipped with optional water-resistant electronic
control unit: the operator panel is built into a separate switch cabinet.
K Dispenser head
– Optionally equipped with printer or applicator
L Dispensing edge
– The label separates from the backing material here.
M Drive roller unit of the label feed
– Pulls the label ribbon incrementally over the dis-
pensing edge. A label is dispensed with each incremental movement.
N Label feed pressure roller
– Presses the label ribbon against the drive roller unit.
O Rewind unit dancer arm and deflection rollers
– 3 fixed deflection rollers
– A spring-loaded, pivoting dancer arm
P Rewind unit
– An electrically driven rewinding roller takes up the
empty backing material.
– A spreader mechanism secures the backing material
roll.
14
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
2.1.2 Principle of operation
[3] Labeller ALS 350 operationally ready with label ribbon
A
B
C
E
D
F
H
G
I
15
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
In labelling mode, the drive roller unit [2B] transports
the label ribbon from the unwinding spool [2A]. A loop
is formed in the label ribbon below the pressure roller of
the unwind unit [2C] and the braking brush [2D]. The
feed roller unit [2F] behind the dispenser head [2E]
pulls the ribbon over the dispensing edge. The label
separates from the backing material at the dispensing
edge and is transferred onto the product.
The feed roller unit moves the respective ribbon for a
label and then stops until the next product is transported to the dispensing edge. Label ribbon is continu ously
unwound at the unwind unit. The loop acts as a buffer
between the continuously operating unwind un it an d
the periodically operating label output. The braking
brushes keep the label ribbon taut.
From the dispensing head, the empty backing materia l
runs over several deflection rollers [2H] and the springloaded, pivoting dancer arm [2G] to the motor-driven
spreader rewinding unit [2I]. The multiple deflections
with the spring-loaded dancer arm act as a buffer between the label output and the rewind unit. When in
operation, the dancer arm pivots back and forth constantly.
The entire operation of the labeller is electronically controlled and monitored. If a malfunction occurs, the control system sends a corresponding message to the
operator. If necessary, the labelling operation is automatically halted. An electronic signal is issued at the
same time. The signal can be picked up and evaluated
by an external control system.
16
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
2.1.3 Technical data
Characteristic values
Labels
Ambient conditions
Dimensions
Casing
Electrical system
1) Customer options
Control system
Emissions
Labelling speed: 0.2 m/min to 55 m/min
Labelling performance: Refer to the service guide
Stop accuracy (at the
dispensing edge): ± 0.5 mm
Unwind unit: Smooth unwinding spindle
Rewind unit: Spreader mechanism
Operation: Programmable, can be set
via the operator panel,
11 data bases available
Speed control: Automatic dispensing
speed, with RPMtransmitter
Label width
(incl. backing material): 10 mm to 155 mm
Label length maximum 350 mm
at maximum dispensing speed: 16 mm to 250 mm
Label roll
Outer diameter: maximum 400 mm
Core diameter: 76.2 mm
Temperature
Operation:
Storage:
5 °C to 40 °C
5 °C to 70 °C
Relative humidity: 30 % to 80 %,
not condensing
Dimensions
Width:
Height:
Depth:
735 mm
795 mm
400 mm
Weight 70 kg
Covering for the control
electronics:
Polyurethane (PUR),
10 mm thick
Front plate: Aluminium, anodized,
15 mm thick
Power consumption: 500 VA
Mains connection
Nominal voltage: 110 V/120 V/130 V/200 V/
220 V/230 V/240 V
1)
Frequency: 50 Hz / 60 Hz
1)
Type of protection
IP41: protected against vertically
falling drops of water, not
protected against sprayed
water
IP54 (optional): Protected against splash-
ing water and dust layers
Drive system
IP41: 2 stepper motors,
1 AC motor
IP54 (optional): 3 stepper motors
Control electronics:
IP41: Integrated
IP54 (optional): The electronic control unit
and operator panel are
built into a separate switch
cabinet
Options: – Serial interface
– Roll diameter control
Sound pressure level at
a distance of 1 m: 75 db (A)
17
2EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
2.1.4 Design versions
The ALS 350 labeller is available in 2 different versions,
depending on the direction of the conveyor line:
Right-hand version
– The products are conveyed from left to right [4].
– The dispensing edge is located on the right side.
Left-hand version
– The products are conveyed from right to left [5].
– The dispensing edge is located on the left side.
Labeller operation is described in these instructions based on the right-hand design version.
The left-hand version is only considered if its
descriptions or illustrations differ significantly.
[4] Right-hand version
A ALS 350 labeller
B Product on conveyor line
C Labelled product
[5] Left-hand version
A
B C
18
2EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
2.2.1 Structural elements
[6] Right-hand version of the ALS 450 Labeller
I
C
A
E
G
K
J
L
M
P
F
D
O
N
Q
H
B
2.2 OVERVIEW OF THE ALS 450
19
2EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
A Unwind unit
– The unwinding spindle holds the label roll.
– A spreader me ch an ism secures the label roll.
B Dance r arm of th e unwin d un it
– Spring-loaded and rotatable
– Assists in the flawless unwinding of the label ribbon
from the unwinding spindle
C G uiding rod for unwind unit
– Secures the label roll on the unwinding spindle.
D Unwind unit deflection roller
E Drive roller unit o f th e unwin d un it
– Pulls the label ribbon evenly from the label roll and
transports it into the loop space.
F Pressure roller of the unwind unit
– Presses the label ribbon against the drive roller unit.
G Braking brush
– Allows label ribbon to run smoothly, prevents flutter-
ing.
H Loop space
– Shaft located below the pressure roller and the
braking brush.
– In this area the label ribbon forms a loop.
ICasing
– Houses the control electronics, drive electrical sys-
tem, main switch, and fuses.
– If equipped with optional water-resistant electronic
control unit: the electronic control unit, drive electri-
cal system, and electrical fuses are built into a sep-
arate switch cabinet.
J Mounting brackets
– For securing the machine in the system.
K Operator panel
– Used to enter commands into the machine and to
display operating states and error messages
– If equipped with optional water-resistant electronic
control unit: the operator panel is built into a separate switch cabinet.
L Dispenser head
– Optionally equipped with printer or applicator
M Dispensing edge
– The label separates from the backing material here.
N Drive roller unit of the label feed
– Pulls the label ribbon incrementally over the dis-
pensing edge. A label is dispensed with each incremental movement.
O Label feed pressure roller
– Presses the label ribbon against the drive roller unit.
P Rewind unit dancer arm and deflection rollers
– 3 fixed deflection rollers
– A spring-loaded, pivoting dancer arm
Q Rewind unit
– An electrically driven rewinding roller takes up the
empty backing material.
– A spreader mechanism secures the backing material
roll.
20
2EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
2.2.2 Principle of operation
[7] Labeller ALS 450 operationally ready with label ribbon
B
C
D
F
E
G
I
H
J
A
21
2EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
In labelling mode, the drive roller unit [7C] transports
the label ribbon from the unwind mandrel [7A] around
the dancer arm [7B]. The dancer arm keeps the label
ribbon constantly taut and slightly under tension. A loop
is formed in the label ribbon below the pressure roller of
the unwind unit [7D] and the braking brush [7E]. The
feed roller unit [7G] behind the dispenser head [7F]
pulls the ribbon over the dispensing edge. The label
separates from the backing material at the dispensing
edge and is transferred onto the product.
The feed roller unit moves the respective ribbon for a label and then stops until the next product is transported
to the dispensing edge. Label ribbon is continuously
unwound at the unwind unit. The loop acts as a buffer
between the continuously operating unwind un it an d
the periodically operating label output. The braking
brushes keep the label ribbon taut.
From the dispensing head, the empty backing materia l
runs over several deflection rollers [7I] and the springloaded, pivoting dancer arm [7H] to the motor-driven
spreader rewinding unit [7J]. The multiple deflections
with the spring-loaded dancer arm act as a buffer between the label output and the rewind unit. When in operation, the dancer arm pivots back and forth
constantly.
The entire operation of the labeller is electronically controlled and monitored. If a malfunction occurs, the control system sends a corresponding message to the
operator. If necessary, the labelling operation is automatically halted. An electronic signal is issued at the
same time. The signal can be picked up and evaluated
by an external control system.
22
2EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
2.2.3 Technical data
Characteristic values
Labels
Ambient conditions
Dimensions
Casing
Electrical system
1) Customer options
Control system
Emissions
Labelling speed: 0.5 m/min to 55 m/min
Labelling performance: Refer to the service guide
Stop accuracy (at the
dispensing edge): ± 0.5 mm
Unwind unit: Unwinding spindle with
spreader mechanism
Rewind unit: Spreader mechanism
Operation: Programmable, can be set
via the operator panel,
11 data bases available
Speed control: Automatic dispensing
speed, with RPM-
transmitter
Label width
(incl. backing material): 10 mm to 230 mm
Label length
at maximum dispensing speed:
maximum 350 mm
16 mm to 250 mm
Label roll
Outer diameter:
Core diameter:
maximum 400 mm
76.2 mm
Temperature
Operation:
Storage:
5 °C to 40 °C
5 °C to 70 °C
Relative humidity: 30 % to 80 %,
not condensing
Dimensions
Width:
Height:
Depth:
735 mm
795 mm
560 mm
Weight 85 kg
Covering for the controlelectronics:
Polyurethane (PUR),
10 mm thick
Front plate: Aluminium, anodized,
15 mm thick
Power consumption: 500 VA
Mains connection
Nominal voltage: 110 V/120 V/130 V/200 V/
220 V/230 V/240 V
1)
Frequency: 50 Hz / 60 Hz
1)
Type of protection
IP41: protected against vertically
falling drops of water, not
protected against sprayed
water
IP54 (optional): Protected against splash-
ing water and dust layers
Drive system
IP41: 2 stepping motors,
1 AC motor
IP54 (optional): 3 stepping motors
Control electronics:
IP41: Integrated
IP54 (optional): The electronic control unit
and operator panel are built
into a separate switch cabinet
Options: – Serial interface
– Roll diameter control
Sound pressure level at
a distance of 1 m: 75 db (A)
23
2EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
2.2.4 Design versions
The ALS 450 labeller is available in 2 different versions,
depending on the direction of the conveyor line:
Right-hand version
– The products are conveyed from left to right [8].
– The dispensing edge is located on the right side.
Left-hand version
– The products are conveyed from right to left [9].
– The dispensing edge is located on the left side.
Labeller operation is described in these instructions based on the right-hand design version. In
general, the labeller ALS 350 (without dancer
arm on the unwind unit) is depicted in the illustrations. The left-hand version and the ALS 450
are only considered if their descriptions or illustrations differ significantly.
[8] Right-hand version
A ALS 450 labeller
B Product on conveyor line
C Labelled product
[9] Left-hand version
A
B C
24
2EQUIPMENT DESCRIPTION
2.3 OPTIONS
ALS
350
450
Serial interface
– Almost all of the setting values can be read out and
modified on an external device, the machine status
can be queried, and the machine can be controlled
via this interface.
– For further information, refer to the Service guide
Roll diameter control
– A sensor at the unwind unit monitors the diameter of
the label roll and, along with it, the supply of labels.
– The sensor sends a signal when the diameter of the
label roll reaches a set value.
– This sensor is required if two labellers are operating
in tandem mode (see chapter Operation – Activation
and shut-down, page 46)
Adjustable dispensing edge
– The position of the dispenser head can be adjusted
vertically.
– This allows adapting the position of the dispensing
edge to changing products.
– The machine does not have to be moved to adjust
the dispensing edge, the labelling head of the machine does not have to be released.
Spring-loaded dispensing edge
– The dispensing edge is pivotably mounted onto the
dispenser head. A torsion spring in the dispenser
head presses the dispensing edge downward onto
the surface of the product.
– Enables height differences between the products or
surface characteristics differences to be com p en sated for.
Pneumatic dispensing edge
– The dispensing edge is pivotably mounted onto the
dispenser head. Compressed air presses the dispensing edge downward onto the surface of the
product.
– Enables height differences between the products or
surface characteristics differences to be compensated for.
Printer
– Inkjet or heat transfer printer at the dispenser head.
Applicator
If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator.
Various kinds of applicators are available depending on
the customer’s needs.
Water-resistant electronic control unit
– Protected against splashing water as per type of
protection IP54
– The control electronics, drive electrical system,
electrical fuses and operator panel are built into a
separate switch cabinet
– Driven exclusively by stepper motors
– Motors are protected against splashing water
2.3 OPTIONS
25
2EQUIPMENT DESCRIPTION
2.4 OPERATOR CONTROLS
ALS
350
450
2.4.1 Operator panel
LED indicator
– Display of functions, setting values, operating
states, error messages, and warning messages
If the LED indicator is ON:
– The machine is in labelling mode.
– Each time the product sensor is triggered, a label is
dispensed.
If the LED indicator is OFF:
– Labelling mode is switched off.
Keys
FEED
– When this key is pressed, the machine dispenses a
label.
PRIOR (previous function)
– Paging through the functions in the menu: to see the
previous function, page upward.
– Within a function: raise the current value, e.g. in-
crease dispensing speed.
NEXT (next function)
– Paging through the functions in the menu: to see the
next function, page downward.
– Within a function: reduce the current value, e.g. de-
crease dispensing speed.
ENTER
– Activate or switch off labelling mode.
– Call up or end functions.
– Acknowledge error and warning messages.
Depending on the menu and the operating
state of the machine, special key functions are
also available. Where special functions are
available, they are described in the relevant
chapter.
[10] Operator panel of the ALS 350 (same design as ALS 450 oper-
ator panel)
A LED indicator
B FEED key
C PRIOR key
D NEXT key
E ENTER key
A
B
C
D
E
2.4 OPERATOR CONTROLS
26
2EQUIPMENT DESCRIPTION
2.4 OPERATOR CONTROLS
ALS
350
450
2.4.2 Main switch
– The main switch [11] is located to the left on the
housing.
– The main switch is used to switch the machine on
and off.
WARNING!
Contact with energised components can result in life-endangering currents through the
body as well as burns. Voltage continues to
be present in the housing even when
switched off.
£ Only put the machine into operation when
installed in a correctly installed housing.
£ Maintain the machine in a dry condition.
[11] Main switch on the housing
A
27
2EQUIPMENT DESCRIPTION
2.5 CONTROL SYSTEM
ALS
350
450
2.5.1 Brief description
All of the machine’s functions are electronically
controlled. Using the operator panel, the operators,
calibration technicians, or service personnel have
several options for adapting the machine's functions to
current requirements.
The LED indicator gives the operator feedback messages regarding the current operating state of the machine. Error messages or warning messages appear on
the display as necessary.
Before each operation, the operator must check and
adjust the occasionally changing settings such as the
label position on the product or the dispensing speed.
These settings can simply be input at any time by the
operator at the operator panel.
Task-specific data such as label distance or product
length are programmed at the beginning of a job. As a
rule, the settings are not modified as long as the job is
being processed. This data input requires in- de p th
knowledge and may only be carried out by trained and
instructed personnel (calibration technicians).
Databanks are available for variable or frequently recurring task settings. The task-specific settings can be
saved in a databank. If the settings are neede d ag a in
after a product change, it is not necessary to re-input
the data. You only need to call up the corresponding
databank. In all, 11 databanks are available.
Only calibration technicians may administer the product
databanks.
It is also possible to modify the basic machine settings.
These are settings such as the motor’s direction of rotation. These settings are not to be changed in normal
operation. They may only be changed by servicing personnel or the customer service.
To give the operator a better overview, the setting options for occasionally changing settings, task-specific
data, databanks, and basic settings are grouped together in menus: The standard menu, extended menu,
product databanks, and configuration menu. The following table provides an overview of the range of functions of the standard menu, extended menu, and
product databanks. The configuration menu is described in the service guide.
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and system, and can even cause work-related accidents!
– Only specially trained and instructed per-
sonnel may alter the settings in the extended menu or access the product
databanks.
2.5 CONTROL SYSTEM
28
2EQUIPMENT DESCRIPTION
2.5 CONTROL SYSTEM
ALS
350
450
2.5.2 Menus for operators and calibration technicians
Menu Standard menu Extended menu Product databanks
Functions ON ON ON
OFF OFF OFF
INIT INIT PD01
VELO VELO PD02
STOD STOD PD03
POS POS PD04
POS 2 PD05
POS 3 PD06
VERT PD07
CONT PD08
E–SS PD09
LPIT PD10
PRDL PD11
P_S_
S_S_
MLAB
PDT
PDWT
EGRA
TMOD
APPL
APT1
APT2
APT3
APT4
LOAD
SAVE
DEL
QUIT
Activating a
menu
Main switch + NEXT PRIOR + NEXT Main switch +
PRIOR
29
2EQUIPMENT DESCRIPTION
2.5 CONTROL SYSTEM
ALS
350
450
2.5.3 Monitoring functions
During labelling operation, the electronic control system and the sensors monitor the following functions.
Dispensing a label to each product
– A photoelectric sensor (product sensor) sends a sig-
nal when a product reaches the dispensing
edge [12B]. The signal from the product sensor trig-
gers the label feed for a single label.
– If individual labels are missing from the label ribbon,
the label feed compensates for this and advances
the label ribbon by one additional label distance (la-
bel compensation).
– If label compensation does not take place before the
next start signal of the product sensor, the product
does not get labelled. A warning message appears
at the operator panel.
– If the number of unlabelled products exceeds a cer-
tain value, the machine stops.
Label supply
– If no more labels arrive at the label stop
sensor [12A] [13A], the machine stops and sends a
signal to the output to the system controller.
– Roll diameter control (optional) [12D, E]:
If the diameter of the label roll on the unwinding
spool [12C] becomes too small, the control system
sends a warning message and a signal to the output
to the system controller. The diameter at which the
signal will be sent can be set by servicing techni-
cians.
If errors occur
If a malfunction occurs, the control system sends a corresponding message to the operator. If necessary, the
labelling operation is automatically halted. The machine simultaneously sends a signal to the system controller.
[12] A Label stop sensor
B The product sensor sends a signal when the product has
reached the dispensing edge.
C Label roll on the unwinding spool
D Photoelectric sensor of the optional roll diameter control
E Reflector of the roll diameter control
[13] Backing material with a label under the label stop sensor (A)
B
A
C
D
E
A
30
3PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
ALS
350
3.1.1 Prerequisites
£ Verify flawless functioning of the safety equipment.
£ Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
£ Non-required materials and objects are to be re-
moved from the working area of the machine.
£ Make sure that only persons authorised to work on
the machine are within the working area of the ma-
chine.
£ Use required personal safety gear in accordance
with the regulations, e.g. wear hair nets, and protec-
tive eye-glasses.
– The label dispenser is switched off at the main
[14A] switch.
3.1.2 Insert the label roller
WARNING!
Risk of injury due to moving or rapidly rotating parts!
£ Before inserting the label roller, ensure
that the machine is switched off at the
main switch.
£ Never switch on the machine before the la-
bel ribbon has been completely threaded
into position.
Remove the old backing material
If backing material remains on the rewinding [15A]
roller:
£ Swing the lever [15C] at the rewinding roller over the
red [15B] point.
– The tension of the rewinding roller spreader mecha-
nism is relieved.
£ Remove the rewound backing material.
Remove adhesive residues
£ If necessary, clean the following components:
– Dispensing edge
– Deflection rollers
– Drive roller
– Rewinding roller
£ Observe the notices in chapter Care and cleaning,
Page 86.
[14] Main switch on the housing
[15] Remove the backing material from the rewinding roller
A Old backing material
B Red point on the rewinding roller
C Lever for the spreader mechanism of the rewinding roller
A
C
A
B
3 PRIO R TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
Loading...