How it Works
Avery Dennison
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ALS 430
User Manual
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Avery Dennison ALS 330, ALS 430 User Manual

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usgabe 08/07
A
rtikelnummer: 0089999-06
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ALS 330/430
Release 8/07 Contents
Contents
1. Important Notes........................................................................................................5
1.1 Overview....................................................................................................................................... 5
1.1.1 Manufacturer...................................................................................................................... 5
1.1.2 Copyright............................................................................................................................5
1.2 Safety............................................................................................................................................6
1.2.1 General Safety Notes ........................................................................................................6
1.2.2 Warning Notes in the Text................................................................................................. 6
1.2.3 Operator’s duty of care...................................................................................................... 7
1.2.4 Concrete security regulations and symbols used.............................................................. 8
1.2.5 Security measures during normal operation......................................................................9
1.2.6 Security measures during maintenance and repairs......................................................... 9
1.2.7 Work on the electrical equipment .................................................................................... 10
1.2.8 Work on pneumatic equipment........................................................................................ 10
1.2.9 Observe environmental regulations.................................................................................10
2. Description .............................................................................................................11
2.1 Mechanics ..................................................................................................................................11
2.2 Operator panel............................................................................................................................ 13
2.3 Plug board.................................................................................................................................. 14
2.4 Electronics..................................................................................................................................15
3. Preparing the machine...........................................................................................17
3.1 Installation ..................................................................................................................................17
3.1.1 Unpacking of the unit....................................................................................................... 17
3.1.2 Connection of the machine.............................................................................................. 17
3.1.3 General setting ................................................................................................................17
3.2 Prepare dispensing.....................................................................................................................17
3.2.1 Insert material..................................................................................................................17
3.2.2 Define label data..............................................................................................................18
3.2.3 Capacitive label sensor....................................................................................................20
3.3 Label guide.................................................................................................................................21
3.4 Adjust dispense function.............................................................................................................21
3.4.1 Stop position....................................................................................................................21
3.4.2 Fixed dispensing speed................................................................................................... 22
3.4.3 Automatic dispensing speed (APSF)............................................................................... 22
3.4.4 Label position on the product...........................................................................................22
3.4.5 Product data bank............................................................................................................ 22
4. Operation ...............................................................................................................23
4.1 Safety recommendation..............................................................................................................23
4.2 Inserting label material ...............................................................................................................24
4.2.1 Removing label material.................................................................................................. 25
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4.2.2 Mounting a new label roll .................................................................................................25
4.2.3 Adjusting the pressure roller ............................................................................................27
4.2.4 Lead screw adjustment....................................................................................................28
4.2.5 Adjustment of the dispensing edge..................................................................................28
4.2.6 Printer adjustment............................................................................................................28
4.2.7 Adjust pressure roller.......................................................................................................29
4.3 Initializing new label material......................................................................................................29
4.4 Control of dispense unit..............................................................................................................30
4.4.1 Dispenser Menu selection................................................................................................30
4.4.2 Missing label function and web breaks............................................................................30
4.4.3 Display and data input......................................................................................................31
4.5 Maintenance ...............................................................................................................................34
5. Menu structure....................................................................................................... 37
5.1 Standard menu ...........................................................................................................................39
5.2 Extended standard menu............................................................................................................41
5.3 Product menu..............................................................................................................................47
6. Configuration menu................................................................................................43
6.1 Handling the menu......................................................................................................................44
6.2 Menu functions............................................................................................................................45
7. Serial interface....................................................................................................... 51
7.1 Data of the serial interface..........................................................................................................51
7.2 Interface commands ...................................................................................................................52
8. Connections and signals........................................................................................55
8.1 Output signals.............................................................................................................................55
8.1.1 Error and warning output..................................................................................................55
8.1.2 Printer output....................................................................................................................55
8.1.3 OD-Control output............................................................................................................55
8.1.4 Ready output....................................................................................................................55
8.2 Applicator modes........................................................................................................................56
8.2.1 Signals for direct dispense...............................................................................................56
8.2.2 Control signals for the ASA applicator.............................................................................57
8.2.3 Signals for the EP applicator............................................................................................58
8.2.4 Applicator connector ........................................................................................................59
8.3 Input signals................................................................................................................................60
8.3.1 Product sensor.................................................................................................................61
8.3.2 OD Control sensor ...........................................................................................................62
8.3.3 APSF sensor....................................................................................................................63
8.3.4 Control signals .................................................................................................................64
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8.4 EMI .............................................................................................................................................66
8.5 Electronic diagrams....................................................................................................................67
9. Errors and warnings...............................................................................................73
9.1 Dispenser error messages .........................................................................................................73
9.2 Dispenser warnings.................................................................................................................... 75
10. Technical specification...........................................................................................77
10.1 Technical Information................................................................................................................. 77
10.1.1 Application specification ..................................................................................................78
10.1.2 APSF- Sensor Specification (Optional function).............................................................. 78
10.2 Performance charts.................................................................................................................... 79
10.2.1 Charts 330 .......................................................................................................................79
10.2.2 Charts 430 .......................................................................................................................81
11. Adjustment.............................................................................................................85
12. Index ......................................................................................................................87
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1. Important Notes
1.1 Overview
The ALS 330 and 430 are fully automatic labeller. Handling is very easy and can be learned with a minimum of training. For operation, only a few adjustments are necessary. The machine is controlled by a microprocessor and because of its programmable functions, it can be used in many applications.
Except of cleaning the rollers and the label sensor there is no periodical maintenance necessary. This manual should help you to operate the machine. In chapter 3 the machine is described and many expressions are explained. For normal operating chapters 4 and 5 are important. All other chapters give additional details of the machine.
Note: This manual applies to ALS 330 and 430 machines, which are equipped with firmware version 7.0.
For technical questions, particularly in case of problems, your local service organisation will be pleased to help you.
1.1.1 Manufacturer
This machine was built by:
Avery Dennison Deutschland GmbH
Ohmstraße 3
85386 Eching
Germany Tel. +49-08165-925-0 FAX +49-08165-3143
1.1.2 Copyright
© 2007 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.
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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:
y
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.
y
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 regulation, 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 instructions 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 330 and 230mm for a 430 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 (Figure 2) of the 330/430 is shown below, it has a 4 digit LED display and 4 membrane keys.
Figure 2 Operator panel
The 4 membrane keys have following functions:
FEED: By pressing this key one label will be dispensed. When the machine
displays INIT pressing this key will start initialisation of the machine. An initialisation has to be made each time a new material is used. If the FEED key is pressed and held as the machine is turned on then the machine carries out an automatic initialisation of the label parameters "CONT" and "LPIT".
PRIOR: This key moves up the menu or increases the value of a (Prior function)
parameter. If the up arrow key is pressed and held as the machine is turned on the product menu is selected.
NEXT: This key moves down the menu or decreases the value of a (Next
function) parameter. If the down arrow key is pressed and held as the machine is turned on the standard menu is selected.
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ENTER: This key is used to enter or exit a menu point or to cancel a warning or
error message.
When the keys have different meanings, it will be explained in the relevant menu description.
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, 220 or 240 V). You carry this out by taking off the fuse holder and position the fuse holder insert accordingly.
Product
APSF-Sensor
Applicator
SPS control
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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. 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.
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3. Preparing the machine
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 Installation
3.1.1 Unpacking of the unit
• For removing the unit off the box, don’t hold the machine on the dispensing edge to prevent disadjustment off the machine.
• For mounting the machine, a complete system of holding tools is available. Ask your representative.
• Take care that the machine is safe and stable mounted.
• There are rotating parts on the machine. Do the necessary actions to prevent that anybody
can be caught from these parts.
3.1.2 Connection of the machine
Before connecting the machine to the mains, check the correct setting of the line voltage. For the connection of sensor, applicators e.g. see the chapter connections. Fix all cables to prevent accidents and damaging of cables. Have also a look to the EMI chapter for proper machine operation. For checking of correct operation of sensors, applicators use the check functions SCHK, I_CH and O_CH.
3.1.3 General setting
Normally the setting is done, but before operation check and note the general dispenser configuration: dispenser direction, machine type, applicator mode, and APSF function.
3.2 Prepare dispensing
3.2.1 Insert material
Insert your label material in the machine to follow the instructions in the chapter Operation / Threading.
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3.2.2 Define label data
For correct dispenser operation, you have to tell the machine the length of the label and adjust the label sensor. Normally this is done automatically. For this follow the instructions in chapter Operation / Initialise material.
There are some reasons the automatic initialisation is not possible:
1. Using another then the standard optical label sensor
2. Label material with a low contrast ratio between label and backing paper
3. Labels with holes inside the label In this case, you have to set one or both of the parameter manually. Activate the extended standard menu to do the settings by:
y
Pressing both keys NEXT and PRIOR simultaneously Display: CODE
y
Password CODE entering: 1 time pressing the key PRIOR FUNCTION 2 times pressing the key NEXT FUNCTION 3 times pressing the key ENTER Display: LPIT
y
Setting the label length
Enter the LPIT function by pressing ENTER. Measure the distance from one label edge to
the edge of the next label. Enter the value in mm by using the function keys. Press ENTER
to leave the function. See also the information below.
y
Change the setting of the label sensor
If another label sensor then the Wenglor type will be used, call the CONT function and set
the value to any manual value (e.g. M006.). If the contrast ratio is low, follow the instructions to adjust manually contrast.
y
To store the setting permanent leaves the menu with the QUIT function. If you power off the
machine without quit all modification are lost.
y
By pressing the key FEED one label can be dispensed if you are in the parameter selection.
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Setting LPIT manually
To initialise labels with cut outs such as the one shown below - the "LPIT" parameter should be used to enter the label pitch of the label web.
Sensor signals
Label sensor
LPIT
real leading edge of label
Figure 4 Definition of LPIT
All other label edges seen by the label sensor will be ignored until the distance adjusted in the "LPIT" parameter has been fed through the label sensor.
Manual adjustment of the CONT parameter
y
Remove a label from the backing paper and slide it inside the sensor.
y
Reduce the value with the PRIOR key until the LED switched on.
y
Press the key NEXT until the LED switched off. If there are marks an the backing paper do the measurement on this position.
y
Note the value GAP xxx
y
Slide the backing paper including label inside the sensor. Use the lightest position on the label for the adjustment.
y
Increase with the NEXT key the value until LED lights again. Note the second value GAP yyy
y
Calculate the contrast value by the formula (xxx + yyy) / 2 and set it.
y
Manual adjustment is completed.
With a difference of less than 20 an operation with this kind of sensor is not possible (sometimes two or more labels are dispensed).
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3.2.3 Capacitive label sensor
For transparent labels the standard photo label sensor doesn’t work. In this case, use a mechanic or a capacitive label sensor.
Note: For correct automatic initialisation, the CONT parameter has to be set to a manual value, if you using not the standard photo sensor.
A mechanical sensor is limited in the speed. The bounce at the label edges produces wrong signals.
There is optional a capacitive label sensor available (Leuze GK14/24L). Adjustment of the sensor is carried out as follows (Figure 5):
1. Set sensitivity to maximum by turning the Potentiometer clockwise. Then rotate ½ turn
anticlockwise.
2. Remove label material out of sensor.
3. Perform base adjustment, that both LED “base adjustment” have the same brightness.
4. Put label with backing paper inside the sensor. Doing this, the LED “switch output” and the
left LED “base adjustment” are switched off. With backing paper only in the sensor both LED are switched on. If the LED are lightning with label inside the sensor, increase sensitivity in ¼ turn steps by rotating the sensitivity clockwise.
5. Check the adjustment over the complete length of label. Carry out the above adjustment after mounting, cleaning or increasing sensitivity.
Figure 5 Capacitive sensor
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3.3 Label guide
On some of the axles, they’re guiding clamps. Adjust the clamps near the machine so all have the same distance to the front plate (31.5mm). The outer clamps should be mounted that the guide but not bend the label material. The front of the V-dispensing edge has a rot, which can be adjusted for straighten the material guiding. Spend several labels by pressing the dispenser FEED key. If the material guiding is running out of the guiding way, adjust the rot by loosing two screws at the dispensing edge. With a L-dispensing the adjustment is done by move the tail sheaves behind the dispensing edge.
3.4 Adjust dispense function
For an operation without any trouble and high label accuracy, tree adjustments are required:
• Label position on the dispensing edge: stop position
• Dispense speed
• Label position on the product
The adjustment should be done in the same order, because parameter like the stop position depends on the setting of the stop position and the dispensing speed.
3.4.1 Stop position
The first step is to adjust the stop position. This is the basic adjustment of the dispense process. Also in case of problems with the machine check if the stop position is okay.
Figure 6 Stop position
The stop position should be adjusted so that the label stops at the dispensing edge up to 3 mm behind. For a correct operation of the automatic label compensation, they will compensate a missing label on the web, first the distance between label sensor and dispensing edge has to be defined. Do this by calling the DIST function in the configuration menu. Check the setting by removing a label before the label sensor from the web. Give a start signal to the machine by triggering the start sensor (not the FEED key) and see if the compensation is done on the right position. Do the fine adjustment with the STOD function.
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3.4.2 Fixed dispensing speed
The second step is to adjust the dispense speed. If an APSF sensor is used see 3.4.3. If an applicator is used, then the dispense speed has no influence to the dispense process. Continue with 3.4.4. Set POS to the distance between start sensor and dispensing edge. If installed remove the roller to press the label onto the product. Now try to dispenser one product. If the label has wrinkles reduce the speed VELO. If the product peels out the label, so the stop position of the next label is different to the last position increase the speed. Normally your dispense speed should be a little bit higher than your product speed.
3.4.3 Automatic dispensing speed (APSF)
With a connected rotary encoder, the dispensing speed follows the measured product speed. To adjust the speed use the EGRA function located in the extended standard menu. The measured speed will be displayed in the VELO function. Do the adjustment in the same way described for fixed speed.
3.4.4 Label position on the product
At least adjust the position of the label on the product with the POS function or with the STAD function, if an applicator is in use.
3.4.5 Product data bank
Save your setting in one of the product data banks. If different products and / or labels are in use up to nine different combinations could be stored. Define and store the different product data. The select the product data bank mode by holding the PRIOR key during power on. Switch back to normal mode by holding the NEXT key.
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4. Operation
This chapter describes the operation of the machine.
4.1 Safety recommendation
CAUTION!
y
Before connections to the mains check the correct voltage selection.
y
Use only original spare parts for service.
y
Open of the cover is only allowed authorised personal.
y
Handling of the machine is permitted only trained personal.
y
Be careful on operation, fingers, hair, clothes, jewellery, etc. may be caught by and get into rotating axles.
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4.2 Inserting label material
Attention:
• Before threading the new material, the waste paper should be removed.
CAUTION! - Isertion/exchange of material should be carried out only by especially instructed personal.
Threading of the label material is shown down below on the threading diagrams for the right-hand and the left-hand version.
Left hand version Right hand version
Figure 7 Threading diagram
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4.2.1 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 8 Remove 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.
4.2.2 Mounting a new label roll
Mounting of the new label roll depends on the used machine
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Mounting a new label roll on ALS 330 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.
Figure 9 Unwind unit at ALS 330 Euro
Mounting a new label roll on ALS 430
By means of the knurled screw the collapsible key can be moved further in or out for clamping and releasing the label roll.
Figure 10 Unwind unit at ALS 430
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
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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.
Figure 11 Rewind
4.2.3 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 12 Pressure roller
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4.2.4 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.
4.2.5 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 13 Dispensing edge
4.2.6 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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4.2.7 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 14 Adjust pressure roller
4.3 Initializing new label material
The machine requires data of the label material in use i.e. label length and opacity of the label and backing material. In most cases, those parameters can be scanned during automatic initialisation. This is not always possible. During initialisation, the machine uses its label sensor to determine where the labels are on the label web and the distance between the leading edge of labels (the label pitch) so that they can be positioned correctly.
There are several modes of initialisation:
y
Automatic mode: The machine measure the setting
y
Manual mode: The operator measures the label parameter and keys in the values.
In most cases, initialisation should be executed in fully automatic mode. For fully automatic initialisation, the "LPIT" and "CONT" parameters should be set to "AUTO". Initialisation can be executed by pressing the <FEED key> whenever the message "INIT" is displayed by the machine.
The message "INIT" is displayed in the following cases: a) if the <FEED> key is pressed and held during power up
b) on return to the standard menu after the "CONT" or "LPIT" parameters have been changed
to automatic mode c) on return to the standard menu after the configuration menu has been used d) after clearing the error messages E__0 or E__1 in the standard menu. (If the feed key is
pressed while another parameter is displayed, the data from the last initialisation is held
and the first label edge detected is simply moved to the position defined by the "STOD"
parameter) To start initialisations simply press the <FEED> key when "INIT" is displayed.
The machine will slowly feed the label web while it searches for the gaps between labels and measures the label pitch. When the machine has determined this information it will move the
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first label edge found during the initialisation process to the position that has been adjusted with the "STOD" parameter. After initialisation has been completed successfully, "ON" is displayed. Initialisation can only take place in the standard menu; it is not required in the product menu since all label data is already stored in the machine's memory. After a E__0 or E__1 message has been cleared whilst in the product menu the first label edge detected at the next press of the <FEED> key will be moved to the position defined by the "STOD" value stored in the machine's memory. However, when changing to a new product bank or changing label rolls the FEED key should be pressed once so that the label sensor can find the next leading label edge and move it to the correct dispense position previously defined by the STOD parameter
4.4 Control of dispense unit
4.4.1 Dispenser Menu selection
Turning on the mains switch and at the same time pressing one of the panel keys, you may select between several options:
PANEL KEY & mains switch
Function Display message
FEED Material initialisation INIT NEXT FUNCTION Standard menu ON PRIOR FUNCTION Product menu PD0n ENTER Configuration menu CODE
Press the key as long as the display shows the version number. One of the above mentioned messages appears in the display. Calling the product menu is only possible, if at least one product bank has been programmed. If you do not press a panel key while turning on the machine the same menu is active that has been used before the machine was switched off.
4.4.2 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 correct 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.
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4.4.3 Display and data input
The operator panel controls the operation of the machine. Data can be displayed and changed. The displays have different meanings:
y
Parameter selection:
In the display a parameter is shown, e.g. POS, STAD, or PD02 (product menu no. 02). By
pressing the keys FUNCTION another parameter can be selected. By pressing the key ENTER the data is displayed.
y
Data display:
The display shows the values of the parameters (e.g. 0123) or possible adjustments e.g.
(AUTO). Pressing the FUNCTION keys changes the data value. By pressing the key ENTER the data input is completed and a new parameter is shown.
y
Error display:
If the display shows e.g. E__XX, the dispenser has recognised an error. A warning is shown
by W_XX. As soon as the error has been corrected, you may erase the message by pressing the key ENTER and you will get back to the status the machine was in before the error was indicated.
Note: Data entered in the standard menu are not stored, if the machine is switched off. If you need to store data you have to use the extended menu. Please check if it is of help for you using the product menu in your application.
Display Menu function Function data value
ON Labeller ready OFF Label function suspend POS label position on product Up to 999.9 mm STOD Label stop position at the
dispensing edge
Depends on setting of DIST, Label length and RAMP
VELO Dispensing speed ALS 330: 0.2 ... 25.0 m/min
ALS 430: 0.2 ... 18.0 m/min STAD delay time before labelling starts 0,1 ... 999,9 ms BLOW apply time 0,1 ... 999,9 ms INIT Initialisation of label material
(CONT and LPIT are measured according to label size)
Appears after E__0, E__1 and Power
on + FEED key depressed, or if the
values of CONT and LPIT are
changed
Dispenser active ___________________________________________________ON
The dispenser is able to dispense labels.
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Dispenser stopped ________________________________________________OFF
The dispenser function is stopped. Single labels could be dispensed with the FEED key.
Material initialisation_______________________________________________ INIT
A new initialisation of material is necessary. Pressing the FEED key will start the initialisation.
Label position ____________________________________________________POS
The position of the label can be changed by the parameter POS while the machine is in operation. The display is presented in 1/10 mm and means the distance between product sensor and labelling position of the product. The display value 0500 would mean 50.0 mm. By pressing the key PRIOR the value is increased, i.e. the label is put on later. By pressing the key NEXT FUNCTION the value is decreased and the label is put on earlier. The labelling position is also changed by variation of the product speed. In this case first control you product speed and the dispense speed VELO. Only if both speed matches adjust the position with the POS function.
Figure 15 Label position
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Stop position ___________________________________________________ STOD
The stopping position (STOD) defines the position where the label stops after it has passed the label sensor. The value represents 1/10 mm. In the example 0160 has to be adjusted by pressing the FUNCTION keys. If an increased value is chosen, the label is advanced further, in case of decreased values the position is closer to the label sensor.
Figure 16 Stop position
Dispense speed __________________________________________________VELO
The speed value VELO displays the dispensing speed in 0.1 m/min. The product conveyor speed has to be constant to assure accurate labelling. A change of the product speed causes a different position of the label on the product. In case of inaccurate labelling, it should be verified, if the speed of the dispenser and your product match together. This is done automatically if the optional automatic speed follower (APSF) is installed.
If the machine is equipped with an applicator, two parameters in the standard menu can be changed. The delay time which specifies the moment when the applicator must put the label onto the product and the blow time - how long the applying of the label should take.
Start delay_______________________________________________________STAD
By the aid of the parameter STAD the period of time between the recognition by the product sensor and the dispensing of the label onto the product is determined. The time units are ms, the time is adjusted by the keys FUNCTION.
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Blow on time ___________________________________________________ BLOW
The labelling time BLOW indicates, for how long the applicator should apply the label onto the product. This time is displayed in ms also. BLOW is equivalent to APT2, which is found in the extended menu.
Product menu____________________________________________________ PD0n
This menu can be used for storing data for different labels and products. 15 different sets of product data can be programmed. If you want to switch to another product, select the respective product number by pressing NEXT and PRIOR, then press ENTER. Now the new product data are activated. To change the labelling parameters you can call the extended menu. After leaving this menu, your product data will be automatically updated.
The labeller carries out the labelling of your products completely automatically. Check now and then:
• if there is still enough labelling material on the unwind roll
• if an error has been displayed and the machine no longer effects labelling
• if the label is placed correctly onto the product. If this is not the case, correct the respective
parameter in the standard menu.
Control is even simpler if you use an OD-control. The OD-sensor measures the diameter of the material roll and indicates a warning message W__5 as the label roll diameter gets too small, i.e. there are only a few labels left on the label roll. To the warning output, you may connect an alarm indicator, an optical or acoustic signal can be triggered.
4.5 Maintenance
The machine can be easily maintained and has only a few wear parts. If you change the 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 rollers, the dispensing edge, the material brush, and possibly from the applicator. 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 roller at the dispensing edge for applying the label to the product, check if the roller is damaged or dirty. Replace it 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 has to check. If the backing paper is not wound up accurately, the belts have to be tightened. Check the electrical connections, especially the mains cable for unreliable connection.
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5. Menu structure
The touch panel keys or the optional interface can change labeller parameters. The last entered parameters are the actual ones the machine works with. Programming via the interface is described in chapter Serial interface.
There are 2 levels for parameter adjustments. The first one is for parameter selection. With the keys FUNCTION a parameter is selected. By pressing the keys ENTER the second level can be reached. Pressing the keys FUNCTION can change the parameter values. By pressing ENTER you quit the parameter adjustment and the next menu point is shown. For some functions the change of values is effected immediately, for others when leaving the menu point. Details in the menu functions.
There are 4 different menu structures:
• Standard menu This menu is used for normal operation. The most important parameters for the production can be changed here. The adjustments are lost after turning off the machine.
• Extended standard menu This menu offers additional parameters and functions to those in the standard menu. Any adjustments made in the extended menu are stored on quitting the menu and are maintained even if the machine is then turned off.
• Product menu If data banks are stored in the extended menu, the product menu can be activated. In this menu, programmed data banks only can be selected. Changing parameters in this menu is not possible. When storing data in a new data bank, the current adjustments are saved to the new product data bank. You may change data values of a stored data bank by loading the data from the extended standard menu, modifying them and resaving them in a data bank.
• Configuration menu In this menu, you configure the machine according to your applications. Additionally you have access to service test functions. This menu is mainly dedicated to service technicians. All current parameter settings are stored on quitting the configuration menu and are maintained if the machine is then turned off.
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Power On
at power on
+
at power on
at power on
or
+
CODE CODE
Standard menu Extended menu Product menu Configuration
INIT/ON/OFF INIT/ON/OFF INIT/ON/OFF Direct LPIT PD01 DTST INIT/ON/OFF CONT PD02 P_S_
POS SENS PD03 MACH STOD STOD PD04 MDIR VELO PRDL PD05 MLAB
 POS PD06 APSF
Ô Applicator Ô STAD PD07 APPL
INIT/ON/OFF VELO PD08 I_CH
STAD STST PD09 O_CH
BLOW SLEW PD10 FACT
! EGRA PD11 BAUD
Ô APT1 PD12 PARI Ô APT2 PD13 SBIT
Ô APT3 PD14  DBIT Ô APT4 RECY ASTP
DIST
SAVE
LABC LOAD QUIT PDT QUIT
Direct dispense
Ô Applicator
active
! APSF on  only if Baud
not set to NONE
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5.1 Standard menu
Usually this menu is used for labelling. All important parameters can be changed while the machine is running. After turning power on, the standard menu is active, unless the product menu was on before the machine was switched off. If the product menu is active and you want to use the standard menu, switch off the machine again. Press the key NEXT FUNCTION while switching on the machine and the standard menu is active. In the standard menu you have access to all important parameters for labelling. The number of parameter and its kind depends on how the configuration has been made. Change of parameters is active immediately. Changed values are lost when turning off power. If values need to be stored, the extended standard menu has to be used. All available commands are listed down below.
Display Function Values
ON Normal operation OFF Stop labelling operation INIT
Initialisation of label sensor and label pitch detection
After status of E__0 and E__1
only POS Position of label on the product Up to 999.9 mm STOD
Stop position of label at the dispensing edge
0,0 ..... 200,0 mm
VELO Labelling speed 0.2 ... 30.0 m/min STAD Delay time for labelling with applicator 1 ... 9999 ms BLOW apply time 0.1 ... 999.9 ms
Initialisation ______________________________________________________ INIT
The function INIT is available only, if required for a new initialisation. Which is the case under the following circumstances:
a) Status error message E__0, the feed key was pressed with pressure roller open b) Status E__1, while moving the label web no labels have been recognised over a web
length of 4 labels. c) During power on the FEED key was held depressed. d) CONT or LPIT were changed to automatic mode.
Note: A new initialisation after an E__0 or E__1 message is not absolutely necessary if you sure that the label parameter are all right. Then leave the INIT display with the NEXT key and press only the key FEED to reposition the label at the dispensing edge.
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Label position ____________________________________________________POS
Function: The start position POS defines when the labelling should take place, after the product has passed the product sensor. Changing the value for POS changes the applied label position on the product. Only available if no applicator is used. Range: up to 999.9 mm in steps of 0.1 mm.
Start delay ______________________________________________________STAD
Function: Delay time for the dispensing after the product has passed the product sensor. This value influences the position of the label on the product. Only available if an applicator is used. Range: 1 to 9999 ms
Stop position ___________________________________________________ STOD
Function: Stop position of the label once the label edge has reached the dispensing edge. The STOD value defines the actual stop position of the label in steps of 0.1 mm.
With this adjustment the label can be made to stop directly at the dispensing edge. To make the label stop after the dispensing edge the value of STOD should be adjusted accordingly.
y
Select the parameter STOD by pressing the keys FUNCTION.
y
By pressing the key ENTER the data input is activated.
Range: 0.0 .... 200.0 (mm).
Labelling time___________________________________________________ BLOW
Function: The labelling time defines how long the applicator should blow the label onto the product. Only available if an applicator is used. BLOW is identical with APT2 Range: 1 to 9999 ms
Dispensing speed ________________________________________________VELO
Function: This parameter defines the speed for the label material. Only available if no applicator is used: With an automatic product speed sensor the actual speed is shown. Range : 0.2 ... 30.0 m/min
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5.2 Extended standard menu
The extended standard menu offers additional parameters you may use in your application. On quitting this menu the current parameter settings are stored in memory. Further changes are also written into memory. As long as this menu is active, no labelling is possible. By pressing the key FEED, however, single dispense of labels is possible. To get into the extended standard menu a password CODE has to be entered. The display shows the first menu point. A survey of all parameters is shown below.
Display Function Data value
LPIT Label pitch AUTO/5...999 mm CONT Label sensor contrast value AUTO/1...200 SENS Sensor status LAB or GAP
STOD Stop position of label at the dispensing edge 0.0 .... 200.0 (mm)
PRDL Product length (inhibit of further product- sensor
signals)
AUTO, 5 ... 999 mm
POS Position of label on product Up to 999.9 mm STAD Delay time for start of applicator cycle 1 ... 9999 ms VELO Labelling speed 0.2 ... 30 m/min STST Check adjusted EGRA value see text SLEW Slew speed FAST or SLOW EGRA Electronic gear ratio adjustment 100 to 500
APT1 Dwell time for applicator 1 ... 7500 ms
APT2 Blow on time for applicator 1 ... 7500 ms
APT3 Restart delay 0 ... 5000 ms
APT4 Time constant compensation 0 ... 500 ms
ASTP End of air stream signal -20 ... 50 mm
PDT Printer dwell time OFF - 1000ms
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Display Function Data value
Printer hold time (is 50% PDT)
SAVE Store data in the product data bank PD01 ... PD09
LOAD Load data from a product data bank PD01 ... PD09
QUIT Leave the extended standard menu standard menu
Label pitch _______________________________________________________LPIT
Distance between 2 labels on the label web, measured from leading edge to leading edge. The distance could be set manual or an automatic length measurement is also possible. In case of automatic mode the length is measured with the INIT function. This should be normally done, so label material could be easy changed. Only under special condition the manual mode has to be used. There are three different modes:
AUTO Select automatic measuring mode A111 The automatic mode is on and a distance of 111 mm was measured M111 The manual mode is selected and a length of 111 mm was entered.
Range: AUTO or 5 ... 999 mm.
Label contrast __________________________________________________ CONT
With this function the sensitivity of the standard label sensor could be adjusted. If AUTO is adjusted, the machine scans automatically. The automatic modes doesn’t work with transparent labels. In case of another type of sensor (mechanical or capacitive) the setting has to be manual. There are three different modes:
AUTO Select automatic measuring mode A111 The automatic mode is on and a contrast of 111 was measured M111 The manual mode is selected and a contrast of 111 was entered.
Range: AUTO or 1 ... 200.
Sensor status____________________________________________________SENS
Function: Status of label sensor is indicated, i.e. there is a label in the sensor the abbreviation LAB is displayed and GAP is shown if there is only backing material inside the label sensor. Can be used for all sensor types i.e. mechanical or electronic ones.
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Stop position ___________________________________________________ STOD
Function: Stop position of the label at the dispensing edge. Available: Always
Range: 0.0 .... 200.0 mm
Product length ___________________________________________________PRDL
Function: The product length avoids multi labelling in case of difficult products. Normally it is set to AUTO. This means that the product length is set to the label length. After the product sensor has detected the edge of the product all signals that might be triggered while the product is passing the product sensor are inhibited. This function can be helpful in cases where the product is transparent or has several detection marks or edges. Such a case is shown below.
The product sensor supplies several signals while the product passes the product sensor. If the PRDL is not adjusted according to the dimension of the actual product the warning W_0 may be given of false multiple product detection signals. The defined product length suppresses all signals after the first product sensor signal has been received. By pressing the keys FUNCTION the parameter PRDL is selected. The data input is selected by pressing the key ENTER. If an applicator is fitted to the labeller, the product length is not defined as a distance but as the time that the product needs to pass the product sensor. The time is adjustable between 5 and 9999 ms. Available: Always Range: AUTO or 5 - 999 mm
Label position_____________________________________________________POS
Function: Position of label on the product. Only available if no applicator is used. Range: up to 999.9 mm in steps of 0.1 mm.
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Start delay ______________________________________________________STAD
Function: Delay time for the dispensing by means of an applicator after the product has passed the product sensor. This value influences the position of the label on the product. Only available if applicator is used. Range: 1 to 9999 ms
Dispensing speed ________________________________________________VELO
Function: The labelling speed may be adjusted with the parameter VELO. Values between 0.2 and 30.0 m/min are possible. The speed has to be adjusted so that it matches the product speed. When an applicator is fitted to the machine, this parameter defines how fast the label will be dispensed on to the applicator.
EGRA value check________________________________________________ STST
Use this function to adjust the EGRA value. If the drive-roller speed is higher than that of the conveyor then increase the EGRA value, if it is lower decrease the EGRA value so that the conveyor speed and drive-roller speed match.
Slew speed _____________________________________________________ SLEW
Function: For some situations the labeller can run with a different, higher speed. This occurs during compensation of a missing label on the web, positioning the label at the dispensing edge during initialisation or after pressing the feed button if the APSF-mode is selected. The resulting speed depends on the selection (FAST or SLOW) and the APSF-mode.
SLEW setting FAST SLOW APSF off Max speed VELO APSF on Max speed 12 m/min
Electronic gear ratio adjustment ___________________________________ EGRA
The parameter EGRA appears in the extended menu only after the APSF function has been switched on. The range of the EGRA parameter is 100 to 500, representing from 1 to 5 encoder pulses per millimetre of conveyor movement. The full EGRA range can be used up to 30 m/min conveyor speed. With an applicator there is no realistic limit to the conveyor speed and at very high-speeds an EGRA value at the lower end of the range should be used.
Dwell time_______________________________________________________ APT1
Function: Only used when an EP- applicator is necessary. It defines for how long the pneumatic cylinder is switched on. Available only with applicator. Range: 1 ... 7500 ms
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Blow on time_____________________________________________________ APT2
Function: Only used when an applicator is necessary. It defines for how long the label is blown onto the product. Available only with applicator. Range: 1 ... 7500 ms
Restart delay ____________________________________________________ APT3
Function: This parameter defines the time for a next label dispense after the applicator cycling is completed. Available only with applicator. Range: 0 ... 5000 ms
Time constant compensation_______________________________________ APT4
Used to control the labelling position when using an applicator in conjunction with APSF. The parameter APT4 is set to the time that the label takes to reach the product from the start of the applicator cycle. For blow applicators this will probably be less than 25 ms, for EP (air­cylinder) applicators the time will be much more - possible 60 ms to 100 ms depending on the length of the air cylinder. To calculate the correct value proceed as follows:
Set APT4 to 1. Run the conveyor at a fairly low speed such as 10 m/min and note the label position on the product. Now run the conveyor at a much higher speed such as 25 m/min and note how far the label position has shifted back.
Use the following formula to calculate the correct value for APT4... (LABEL SHIFT (mm) x 60) / (Vhigh - Vlow) = APT4 Vhigh represents the higher conveyor speed used (in m/min)
Vlow represents the lower conveyor speed used (in m/min) eg. If the shift is 3mm and the conveyor speeds 10 m/min and 25 m/min are used the correct
value for APT4 is: (3 x 60) / (25 - 10) = 180 / 15 = 12 The calculated value should then be tested by running the conveyor at a high and a low speed
and checking that the placement position does not change. If the label position moves back slightly at higher speed then increase APT4 a little, if it moves forward at higher speed then decrease APT4 a little.
Note: The EGRA parameter must be set correctly as well as the APT4 parameter for correct label positioning on the product.
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End of air stream signal ___________________________________________ASTP
This parameter determines how long the air stream signal will remain active after the label dispense has finished. Valid in all modes (direct dispense, applicator, APSF and fixed-speed).
Printer dwell time__________________________________________________ PDT
This determines the dwell time of the stamp-printer. A new dispense is prevented after PDT expires for a time equal to 50% of PDT.
Save parameter in data bank _______________________________________SAVE
Function: After selection this function you can save the current parameter setting to a data bank. Always available. Range: NEW1 .. NE15 Create a new data bank
PD01 ... PD15 Overwrite existing data bank EXIT Leave function without modification
Load data bank _________________________________________________ LOAD
Function: After selection this function you may load a predefined parameter setting. Always available. Range: PD01 ... PD15 Load a defined data bank EXIT Leave function without modification
Leave Menu finishing _____________________________________________ QUIT
Function: If this function is selected, you get back to the standard menu Always available.
Note: Modified parameter values are only stored if the menu is left by using the QUIT function. If the power is switched off before leaving the menu by quit all modifications are lost.
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5.3 Product menu
If parameters have to be changed because of different products and labels, the product menu can be used. The machine offers a data bank in which 14 sets of data can be stored.
If you want to switch to a particular product, select one of the product numbers by pressing NEXT or PRIOR and confirm with ENTER .The new parameters are valid now.
After switching to a new product bank the machine assumes the label roll has been changed or that a parameter such as STOD is different and so requires an initialisation of the label position at the dispensing edge. This is done by pressing the FEED key after loading a new product bank at which time the machine will move the first detected label edge to the dispense position.
Note: If the FEED key is not pressed after loading a new product bank the first detected label edge will be moved to the dispense position at the first signal from the product sensor!
Note: The function FACT available in the configuration menu clears all the product banks.
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6. Configuration menu
Adjustments in the configuration menu are necessary during installation of the machine only. In the configuration menu, the required optional functions can be selected. Some service support functions in the configuration menu will be useful for the service staff.
Possible adjustments:
y
Recognition of the product at the leading or trailing edge
y
Left or right hand version of labeller
y
Machine type
y
direct dispensing or several type of applicators
y
Parameters for the interface
Possible tests:
y
In/output test
y
Test run without labelling
The function Factory initialisation resets all parameters to default values.
Calling the configuration menu
There are two ways to call the configuration menu:
y
Press the key ENTER and switching on power at the same time. The display shows 'CODE'.
y
Press the keys NEXT and PRIOR at the same time when a parameter function is displayed. The display shows 'CODE'.
The password has to be entered by pressing the following keys: * 1 time PRIOR FUNCTION * 3 times NEXT FUNCTION * 2 time ENTER * 3 times NEXT FUNCTION
When the password is entered correctly, the display shows `DTST`. After pressing PRIOR or NEXT the next menu, point will be shown. If a wrong password was entered, you go back to the previous menu.
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6.1 Handling the menu
The menu structure is shown in the following table. By means of the key PRIOR you switch to the prior function, and with the key NEXT to the next following function in the menu. If you press the key ENTER the current parameter value of a function is shown. The current parameter value can be changed with the keys PRIOR FUNCTION or NEXT FUNCTION. Values are stored by pressing the key ENTER.
Display Function of the parameter Possible data entry
DTST Test run without labels P_S_ Product sensor detects at leading or
trailing edge of product
LEDG, TEDG
MACH Machine type 230, 720, 330, 430 MDIR Motor running direction for left or right
hand
<---- --->
MLAB Handling of missing label NONE, WARN, ERR1, ERR2,
ERR3 APSF Automatic product speed follower YES, NO APPL Direct dispense mode, or applicators DIR, ASA, EP, RVEP I_CH Test of inputs O_CH Test of outputs FACT Reset of all parameters to default values YES, NO BAUD Baudrate of the interface NONE, 300 to 192% PARI Parity bit NO, 0PRT, ODD, EVEN SBIT Number of Stop bits 1 bit, 2 bit DBIT Number of data bits 7 bit, 8 bit RECY Recycle (simulates max labels/min) see text DIST Distance label sensor to dispensing edge 10 ... 999 mm LABC Number of dispensed labels see text QUIT Return to extended standard menu
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6.2 Menu functions
The menu functions are explained in detail here.
Permanent test___________________________________________________DTST
The permanent test makes a test run without using labels. In the display the numbers of dispense cycles is shown (see description LABC). Immediately after starting the function, the machine runs in a self-test. The test run works with all adjusted parameters. The test can be stopped by pressing the key ENTER.
Polarity of the product sensor ______________________________________ P_S_
The machine requires a start signal for each product to be labelled. After the start delay (STAD) the labelling starts. The signal is usually created by a light sensor at the conveyor. A PLC can also supply this signal. The light sensor supplies a signal when the light beam is interrupted by the product. By means of the function P_S_ it will be selected whether the leading edge or the trailing edge of the product should trigger the signal. Usually the trailing edge of a product is used. Reasons for detecting the leading edge can be:
- shape of product (your should avoid detecting a radius or a declined edge) In case of using other than the standard product sensor’s, the meaning of the display can be
reversed. The adjustment you need you may change with the keys NEXT or PRIOR. Factory adjustment: LEDG
Machine type ___________________________________________________ MACH
The software is identical for several different machines. Choice the correct type. Factory setting: The last setting remains after a factory reset.
Dispensing direction ______________________________________________ MDIR
The machine is available in a right and left-hand version. In the right hand version the product transport is from left to right when you look to the front of the machine. The adjustment is done in the factory and should not be changed.
Factory setting: The last setting remains after a factory reset.
Handling of missing label _________________________________________ MLAB
There are several condition the dispenser is not able to dispense a product:
y
the distance between products is too close
y
an additional printer is not fast enough
y
the loop in the ALX720 is empty (end of job, printer error)
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With this function, you can decide how to react:
NONE Do nothing. The unlabeled product will be detected later in the line. WARN Set the warning output and displays W__0. The production continued. ERR1 Set the error output to stop the production line immediately and display E_10. ERR2 The first unlabeled product generates the warning. Two unlabeled products in a
sequence set the error.
ERR3 The error condition will be set at 3 unlabeled products.
Automatic product speed follower
_________________________APSF
Under parameter APSF the automatic product speed follower function can be activated (ON / OFF). The APSF sensor is fitted to the conveyor and supplies signals that represent the speed of the conveyor. The installation of the sensor and the adjustment of the parameter have been carried out according to your application and should not be changed. The compensation steps for the current conveyor speed are constantly recalculated rather than just when the product-sensor is triggered. This means that a change in conveyor speed between the time that the product is detected and the time it reached the dispense position has no effect on labelling placement accuracy. There is no optimum EGRA setting. The compensation steps are calculated using the current EGRA setting rather than using fixed compensation step values for a predetermined EGRA setting and so any EGRA value works just as well. At slow speeds the label dispense speed matches the conveyor speed exactly regardless of the EGRA setting. For instance if the dispenser needs to make 1.236 steps per encoder pulse then at the first four encoder pulses the dispenser will make one step but will then have fallen 4x0.236=0.944 steps behind. On the fifth encoder pulse the dispenser will make two steps and so be (5x0.236)-1=0.18 steps behind. The dispenser will always be less than one step behind. The dispenser thus always dispenses the correct amount of label in regard to the product movement even when the conveyor is starting from rest or coming to rest.
Type of applicator ________________________________________________APPL
In most cases, the label is dispensed directly onto the product. If this is not possible, an applicator has to be used. We offer a number of different applicators. In this function, the installed applicator has to be defined. You may select the applicator type you have ordered for your application (display shows 'ASA`,`EP`, RVEP or another applicator). In case of direct dispensing the function direct dispense has to be chosen: Display shows 'DIR'. The adjustment is done in the factory and should not be changed.
RVEP (ReVerse EP) operates as an EP applicator except that once the label has been dispensed onto the applicator the applicator cylinder is extended to wait for the next product to arrive. This provides more accurate labelling than with EP applicators because variation in the time it takes for the cylinder to extend does not affect the labelling position.
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Additional functions in the standard menu Depending on which parameter has been defined under APPL different menu functions are shown in the standard menu. If an applicator is used additional times BLOW and STAD for controlling the applicator cycling are available.
Input and sensor check____________________________________________ I_CH
To display the status of sensor’s and inputs information are grouped in 3 blocks you can select by pressing the NEXT or PRIOR keys. The character for the inactive state is different to identify the various blocks.
Block 1 (inactive = 0)
N = Power fail detection (only can case of malfunction) P = Product sensor active A = Signal from APSF sensor R = Ready input stepper motor control
Block 2 (inactive = -)
I = Inhibit input active L = Unused input (Loop control on ALX 720) H = Applicator home switch active E = Applicator end switch active Z = Horizontal home switch
Block 3 (inactive = .)
S = pressure switch activated J = Jumper 3 closed O = OD control material active M = Label sensor on material G = Label sensor on gap
For a correct label sensor information CONT has to be adjusted before. Leave the function by pressing key ENTER.
Output check ___________________________________________________ O_CH
With the NEXT and PRIOR keys you can select the output you will switch on for testing. Leave the function by pressing key ENTER. On selecting the O_CH function the display shows "1" and the first output is active. Using the up-arrow and down-arrow keys the user can select any one of outputs 1 to 8. Only one output is on at a time so that the user can easily see if he has any shorted connections (any output that is being turned on by another part of the program such as an error or ODC output will stay on until the error or ODC input is cleared).
1 = terminal 15 = BLOWON 2 = terminal 16 = AIRSTREAM 3 = terminal 17 = CYLINDER 4 = terminal 18 = PRINT_OUT 5 = terminal 19 = WARNING 6 = terminal 20 = ERROR
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7 = terminal 31 = READY 8 = terminal 32 = ODC_OUT / HORI_CYL
Adjustment resetting______________________________________________FACT
This menu point sets all parameters back to the factory values. All parameters will be reset, so please note all your adjustments before. When you call this function the display shows 'NO`. After you have left by pressing the key ENTER there is no change. When you change with the key NEXT to YES and press ENTER all parameters are reset to default values. Note: This function also clears all product banks.
Interface baud rate_______________________________________________ BAUD
With this function the baud rate of the interface will be adjusted. This is an option of the machine. If you do not have this option, the parameter has to be set to 'NONE` to protect the interface and to avoid errors. The following baud rates are adjustable: 150, 300, 600, 2400, 4800, 9600 and 19200 baud. When calling the function FACT this parameter will be set to `NONE`. When the machine is delivered with the interface the baud rate is set to 9600. Select your baud rate by pressing the key NEXT or PRIOR . With the key ENTER the adjustment is stored. Factory adjustment: NONE
Parity bit ________________________________________________________ PARI
The function is only visible if a baudrate is selected. The parity bit is necessary to check the data transfer. In case of wrong data transfer an error message will be given. The adjustment of both machines has to be identical. Usually the transfer is made without parity bit. Possible adjustments:
'NO`: Not sending or receiving a parity bit `EVEN`: produce a parity bit so that an equal number of `1` signals is created `ODD`: produce a parity bit so that an odd number of '1' signals is created.
`0PRT`: The parity bit is always 0 By pressing the key NEXT or PRIOR the adjustment is selected and by pressing the key ENTER the function is finished. Factory adjustment: NO
Number of stop bits_______________________________________________ SBIT
The function is only visible if a baudrate is selected. This parameter defines the number of stop bits. By pressing the key function you can select between `1BIT` or `2BIT`. By pressing the key ENTER this function will be left. Factory adjustment: 1BIT
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Number of data bits_______________________________________________ DBIT
The function is only visible if a baudrate is selected. With this function you can select between 7 or 8 data bit protocols. Factory adjustment: 8BIT
Recycle (simulates max labels/min) ________________________________ RECY
The Auto-recycle function, is used to determine the maximum possible cycle rate with the current parameter settings. It will cycle through applicator cycles automatically by internally generating a product-start the instant a cycle has been completed and displays the average cycle rate per minute in the display. It also operates with no applicator selected by dispensing labels at the maximum possible rate. The maximum labelling rate for different values of PDT can be determined using the RECY function without having to physically connect the printer.
Distance sensor to dispensing edge _________________________________ DIST
This function defines the distance between the material label sensor and the dispensing edge. This value is shown in steps of 0.1 mm (e.g. 0456 means 45.6 mm). The measured value can be adjusted by pressing the key FUNCTION. If the DIST value has been adjusted correctly the first leading label edge detected at initialisation will be moved exactly to the dispensing edge, as long as STOD is set to 0.0 (mm). This parameter is important for the missing label compensation. If it is not correctly adjusted a missing label on the material roll, will not be compensated correctly and the product will not be labelled.
Value range: 10.0 .... 999.9 mm
Label counter ___________________________________________________ LABC
Each dispensed label increases the counter by 1. The capacity of the counter is for 999 999 999. The total number can be seen in 3 sections, press the keys FUNCTION as described down below:
Mnnn Knnn .nnn
y
where M represents millions
y
K represents thousands
y
.represents units
On entering the "LABC" parameter the units are displayed. By using the arrow keys can then be used to change between the millions, thousands and units displays. By pressing NEXT and PRIOR at the same time the counter is set to 0. By pressing the key ENTER the function will be left.
Leave Menu finishing _____________________________________________ QUIT
Function: If this function is selected, you get back to the standard menu
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Note: Modified parameter values are only stored if the menu is left by using the QUIT function. If the power is switched off before leaving the menu by quit all modifications are lost.
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7. Serial interface
The machine has a serial interface according to the standard RS232C. Via this interface parameters can be adjusted. All received commands are tested for syntax and legal value range. Invalid commands and parameters are ignored. An error message is not given in this case. All commands received over the serial interface are tested for syntax and range; invalid commands and out of range parameter values are ignored. A warning message is not given in these cases. However in the case of framing, parity or overrun errors the warning "W__3" is generated. The commands are made up of sequences of ASCII characters. Each command starts with "#" and "!" followed by a 4 character code. The reception of the "#" character indicates the start of a new command to the machine. The codes are similar to the parameter names shown in the display.
7.1 Data of the serial interface
The pin connection of the interface plug is shown in the table below.
Dispenser connector Signal description PC
25 pol D­Sub
9 pol D­Sub
Direction Code Description 25 pol 9 pol
Socket 2 3 Output TxD Transmit data 3 2 Socket 3 2 Input RxD Receive data 2 3 Socket 5 8 Input CTS Clear to send 4 7 Socket 4 7 Output RTS Request to send 5 8 Socket 7 5 GND 7 5 Socket 20 4 Output DTR 6 6 Socket 24 (if jumper
on)
+ 10V For external use 8 All other pins are not connected. Adjustable data values
Baudrate 150, 300, 600, 1200, 2400, 4800, 9600, 19200 Baud Data bits 7 or 8 bits Stop bits 1 or 2 bits Parity No Parity, Parity bit always 0, odd or even parity Handshake RTS/CTS
Factory interface deactivated, at reactivation the parameters will be set to 8 data bits, 2
stop bits and no parity bit.
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7.2 Interface commands
The below described commands will change one of the labelling parameter. The values are not stored and will be lost when turning off power. If the sequence nnnn is replaced by the character "?" then the current value of that parameter will be returned by the labelling machine as a 4 character string confirming the name of the parameter requested followed by 4 numbers representing the current value of that parameter. The character 04H terminates all return messages.
Example
PC send the message: #!VELO? Machine returns: VELO0300<04H>
Command Description Range
#!APOSnnnn Value APOS
-0050 – 0100 mm
#!APPLnnnn Applicator type 0000 direct dispense
0001 ASA 0002 EP 0003 EP_U 0004 PLUA 0005 INDX
#!APSFnnnn APSF function 0000 off
0001 on
#!APT1nnnn Applicator time
0001 – 7500 ms
#!APT2nnnn Applicator time
0001 – 7500 ms
#!APT3nnnn Applicator time
0000 – 5000 ms
#!ASTPnnnn Value ASTP
-0020 – 0050 mm
#!BANKnnnn Change product bank
0000 - 0009
#!BLOWnnnn Blow on time = APT 2
0001 - 7500 ms
#!COMPnnnn Automatic label compensation 0000 = Off
0001 = On
#!CONTnnnn Material contrast 0001 – 0200
0000 automatically
#!DISTnnnn Distance label sensor – dispensing
edge
0080 – 9999 * 0.1 mm
#!EGRAnnn Gear ratio
0300 – 1000
#!LPITnnnn Label length 0005 – 0999 mm
0000 automatically
#!MACHnnnn Machine type 0000 ALS230
0001 ALX720 0002 ALS330 0003 ALS430
#!MDIRnnnn Motor direction 0000 Right --- >
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Command Description Range
0001 Left < ---
#!MLABnnnn Missing label error 0000 NONE
0001 Warning 0002 Error 1 0003 Error 2
#!PDT nnnn Print dwell time 0001 – 1000 ms
0000 printer off
#!PHT nnnn Printer hold time
0001 – 7500 ms
#!POS_nnn Labelling position
0001 – 9999 * 0.1 mm
#!PRDLnnnn Product length
0005 – 4000 mm
#!P_S_nnnn Polarity product sensor 0000 LEDG
0001 TEDG
#!RAMPnnnn Acceleration Ramp 0000 NORM
0001 FAST
#!SLEWnnnn Slew speed 0000 = FAST
0001 = SLOW
#!STADnnnn Start delay
0001 - 9999 ms
#!STODnnnn Stop position
0080 - 9999 * 0.1 mm
#!VELOnnnn Speed
0020 - 0300 * 0.1m/min
#!SAVEnnnn Store in data bank
0001 - 0009
#!LOADnnnn Load data bank
0001 - 0009
The following described commands do not have parameter values. With these commands the host can monitor and control the machine.
#!CLRC Set label counter to 0 #!CLRE Clear error message #!CLRW Clear warning #!ERRF The machine sends an error status to the monitoring computer. The message
ERR8___4__1_<04H> means, error 8, 4 and 1 have occurred.
#!WARF The machine sends a warning status to the monitoring computer. The message
WARF7______0 means: The warnings 7 and 0 have occurred. #!LABC The machine sends the number of dispensed labels e.g. LABC0000008359 back #!SP__ The machine is set to off. The product sensor is disabled and labelling will
therefore be stopped.
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#!SR__ The machine is set to on. The product sensor is enabled and labelling can
restart.
For a full automatic operation, the following procedure in case of an error is required:
y
#!ERRF Request error
y
#!CLRE Clear error message after fixing the error. The labeller shows „INIT“
y
#!SR__ Clear INIT message
Bit definition in error flag Error number Error message in display Error description
0 E__0 Pressure roller open 1 E__1 End of material (4 missing labels) 2 E__2 EP-applicator error 3 E__3 checksum error configuration data 4 E__4 checksum error parameter bank 5 E__5 Error 10V low 6 E__6 Error 24V low 7 E__7 missing label on product 8 E__8 Error motor driver
Bit definition in warning flag Warning Message in display Warning description
0 W__0 Next product start before finished 1 W__1 Product start but no material not initialised 2 W__2 EEPROM error during write 3 W__3 Interface warning 4 W__4 APSF speed too fast 5 W__5 End of material (OD-Control) 6 W__6 too many products 7 W__7 Loop not ready (720)
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8. Connections and signals
This machine has a number of inputs to connect sensor’s and a control. Outputs are available for applicators, a printer and other purposes.
8.1 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.
8.1.1 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.
8.1.2 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.
8.1.3 OD-Control output
This output is switched active (+24V) if the OD-Control input is switched active during dispensing.
8.1.4 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 requires initialisation
• in OFF condition.
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8.2 Applicator modes
The machine is able to dispense the label direct on the passing product. There is also the possibility to drive without any external control a wide range of applicators.
8.2.1 Signals for direct dispense
For direct dispensing the airstream signal can be used to control a pneumatic driven dispensing edge. The start of the airstream signal (= motor run signal) could be behind the start of the dispense motor, adjusted with the function APT3. The signal is switched inactive, when the label dispense has been completed. Also the stop could be adjusted with the function ASTP to switch inactive before or behind the dispense motor stop.
Ready
Product start
Label start Suppression
Product start Suppression
Dispense
Motor run signal
1
2
3
4
POS
POS
POS
PRDL
APT3
ASTP
ASTP
1
Productstart disabled. PRDL activ
2
Missing Label: New start of dispense during dispenser activ
3
Inhibit activ
4
Machine not ready. Errorcondition or not online
Figure 17 Timing diagram direct dispense
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8.2.2 Control signals for the ASA applicator
For controlling an air stream applicator the signals air- stream and blow on are necessary. The time period APT2 defines how long the blow on signal is active. After labelling the product and the time period of APT3 a new label will be dispensed on to the applicator. After that the machine is ready for a new labelling. All errors are given after 5 seconds!
Productstart
Airstream va lve
STA D
Blowon va lve
APT3
APT2
1
1 Missing Label: Labeller not ready for dispense
STA D
Dispense label
Figure 18 Timing ASA applicator
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8.2.3 Signals for the EP applicator
For controlling the applicator the signals air stream, cylinder valve and blow on are necessary. After a product signal has occurred the labelling cylinder valve is switched active after the delay STAD. However if at this time the applicator is not in the home position then error message E__2 is generated. After the delay time APT1 the blow on valve is switched active for the time APT2. When APT2 is completed both the labelling cylinder valve and the blow on valve signals are switched inactive. If the control does not read the home position in the time given - 3* (APT1+ APT2) - than the error message E__2 is generated.
Productstart
Cylinder valve
Dispense label + Airstream valve
Blowon valve
Homeswitch
12Missing Label: Labeller not ready for dispense
Error: Applicator not in homeposition3
Error: Homeposition not detected
STAD AP T 1
APT3
APT2
1
3
STAD
STAD
APT1 4 * (APT 1 + APT 2)
STAD
2
Figure 19 Timing EP applicator
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8.2.4 Applicator connector
The applicator connection is done via a 15 pole D-sub connector common to other machines.
Figure 20 Applicator connector
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8.3 Input signals
This machine (dispenser) is provided with photo coupled inputs for:
y
the product sensor signal
y
an inhibit signal for inhibiting labelling
y
a signal from an OD control which shows the end of the material roll.
y
a signal from an automatic product speed follower
y
the EP applicator signals from the HOME and END switches
y
an unused input for future extensions or customer specific software (used for loop control in the 720)
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
(alternative switch)
+24V DC
NPN
Opto­isolator
2K2
ln+
Signal
ln-
Machine
(alternative switch)
+24V DC
PNP
Opto­isolator
2K2
Figure 21: Connectin g NPN (left) or PNP (right) inputs.
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8.3.1 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 22 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 23 Example for connecting an PNP sensor (Datalogic)
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8.3.2 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 24 NPN connection of optional ODC sensor
+24V
GND
14
black
green
white red
25
11 27
CN33
brown
5 9 4 8 3 7 2 6 1
Signal-
GND
Signal+
Supply
white
grey
blue
S5-5-C8-30
PNP sensor
5 9 4 8 3 7 2 6
1
Figure 25 PNP connection of optional ODC sensor
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8.3.3 APSF sensor
For the APSF function (Automatic speed follower) a rotary encoder has to be installed. For optimum labelling accuracy the rotary encoder should be selected so that it produces one pulse for every 0.125 mm of product movement. The connection of the encoder should be done with a shielded cable. For correct operation the rise and fall time of the encoder signal should be 1 µs.
+24V
GND
14
black
yellow
white red
5 9 4 8 3 7 2 6 1
GND
Signal
Supply
Shield
12
33 27
CN33
NPN sensor
5 9 4 8 3 7 2 6 1
Figure 26 Connection of a NPN type APSF sensor
+24V
GND
14
black
yellow
white red
12
33 27
CN33
5 9 4 8 3 7 2 6 1
5 9 4 8 3 7 2 6 1
GND
Signal
Supply
Shield
PNP sensor
Figure 27 Connection of a PNP type APSF sensor
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8.3.4 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 Volt +24 Volt
Ground M asse
Warning output Warnausgang
Error output Fehlerausgang
Inhibit - Startunterdrückung -
Inhibit + 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 28 Optional connector for process contro
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l
Figure 29 Internal I/O connector
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8.4 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
mm2.
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.
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8.5 Electronic diagrams
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Figure 30 Wiring diagram
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Figure 31 Layout dispenser electronic board
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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 32 Layout stepper motor driver
JP
Figure 33 Display jumper setting
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9. Errors and warnings
The software checks during the labelling permanently, if the machine runs under normal operation. If labelling is not possible, the display shows a message e.g. E__0. If the labelling can be continued, but a problem has occurred or may occur, the display shows a warning e.g. W__1. By pressing the key ENTER the message will be erased. In case of an error or warning message the relevant output is switched. The signal can be used for interconnection with an external machine control. Via the serial interface the errors and warnings can be called. If an error cannot be erased, please call your local service technician.
9.1 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.
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.
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__2 EP applicator not in HOME
position
Check air supply. Applicator not connected. HOME switch not adjusted
E__3 Check sum of the configuration
data is wrong. All Parameters are set to the factory adjustment.
Call the configuration menu and adjust all parameters again.
E__4 Check sum of the labelling data is
wrong. Labelling Parameters are
All labelling parameter have to be adjusted again
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Message Meaning How to solve
set to the factory adjustment.
E__5 10V supply voltage for label
sensor 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 Material initialization failed Check if the label web is threaded
through the label sensor
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 Missing label on product One or several product could not be
labelled. Distance between products too close. Increase speed of printer.
___0 Process error (Divide overflow) Hardware failure external noise. EPROM
damaged. Turn off power and on again. Change EPROM or main board
___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.
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9.2 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__0
New start signal from product sensor while ALX720 is dispensing a label Multiple signals from the same product Several missing labels on the web, which can not be compensated
Slow down conveyor speed or product sequence. Adjust higher labelling speed Increase the parameter value of PRDL product length
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__3 RS232 transfer error
Check interface parameter in the configuration menu and in the host
W__4
Conveyor speed exceeded the max. speed of the dispenser
Slow down conveyor. If average conveyor speed is OK then check for oscillation in the conveyor speed or vibration of the pulse generator
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
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10. Technical specification
The following data are maximum values. Depending on label material, operation environment and labelling condition the real value could be lower.
10.1 Technical Information
Details
Description
330 430
Label width (incl. backing paper)
10 mm ... 100 mm 10 mm ... 230 mm
Label length 5 to 999 mm Diameter Label roll max 300 mm Core diameter (of label
roll)
1.5" (37 mm), or 3" (74 mm) optional
Label roll unwind dancer arm controlled unwind brake, for minimum
change in web tension (Euro versions only)
Dispensing speed 0.2- 25 m/min 0.2- 18 m/min Material transport 0.1 mm per motor step APSFAutomatic Product
Speed Follower
optionalResolution: 0.1mm to 0.3 mm per pulse
Label stop accuracy +/- 0.5mm Labels per min rate See performance charts Rewind collapsible, i.e. can be used even for plastic backing material Dispensing edge V-shape fixed; L - shape fixed (optional) 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, 4 Membrane keys Label sensor infrared photo sensor CE- marked Confirms all relevant actual European standards Protection class IP 41, IP54 on request
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Details
Description
330 430
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%
10.1.1 Application specification
The labeller is designed and built for automatic applies of self-adhesive labels.
10.1.2 APSF- Sensor Specification (Optional function)
The resolution of the sensor should be selected in a way, that for 0.15mm product travel a sensor pulse will be generated. Using a different resolution gives loose in label accuracy or limits the highest dispensing speed. It is possible to use one common sensor for several dispensers. In this case the sensor is supplied from one machine or the several supply voltages switched parallel are separated with diodes.
Supply voltage: 24 V DC Output current: 20mA for each dispenser Signal rise and fall time: each 1µs Max frequency: 20 kHz Signal ratio: 1:1 +- 12,5 % Connection: Only shielded cable. The shield has to be grounded on both sides.
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10.2 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 V4.0.
10.2.1 Charts 330
0 5 10 15 20 25 30 m/min
labels/min
0
100
200
300
400
500
600
700
800 25 mm
50 mm 75 mm 100 mm 150 mm 250 mm
Figure 34 Performance chart: Ramp FAST
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0 5 10 15 20 25 30 m/min
labels/min
0
100
200
300
400
500
600
700
800
900
1000
1100 25 mm
50 mm 75 mm 100 mm 150 mm 250 mm
Figure 35 Performance chart: Ramp NORM
0 5 10 15 20 25 30 m/min
mm
0
1
2
3
4
5
6 Normal
Fast
Figure 36 Accelaration
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0 5 10 15 20 25 30 m/min
mm
0
1
2
3
4
5
6
7
8 Normal
Fast
Figure 37 Deceleration
10.2.2 Charts 430
0 5 10 15 20 25 30 m/min
labels/min
0
100
200
300
400
500
600
700
800 25 mm
50 mm 75 mm 100 mm 150 mm 250 mm
Figure 38 Performance chart: Ramp FAST
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0 5 10 15 20 25 30 m/min
labels/min
0
100
200
300
400
500
600
700
800
900 25 mm
50 mm 75 mm 100 mm 150 mm 250 mm
Figure 39 Performance chart: Ramp NORM
0 5 10 15 20 25 30 m/min
mm
0
1
2
3
4
5
6
7
8 Normal
Fast
Figure 40 Accelaration
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0 5 10 15 20 25 30 m/min
mm
0
1
2
3
4
5
6
7
8
9
10 Normal
Fast
Figure 41 Deceleration
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11. Adjustment
Function Factory Application
P_S_ LEDG MACH 230 MDIR Å RAMP FAST MLAB WARN COMP ON APSF OFF APPL DIR BAUD NONE PARI NO SBIT 2BIT DBIT 8BIT DIST 76.0 mm PHT 1 SLEW FAST
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Function Factory PD01 PD02 PD03 PD04
POS(STAD) 100.0 mm VELO 30.0 m/min STOD 76.0 mm BLOW(APT2) 1 ms LPIT AUTO CONT AUTO PRDL AUTO EGRA 500 APT1 200 ms APT3 0 ms APOS 0 ASTP 0 PDT OFF
Function PD05 PD06 PD07 PD08 PD09
POS(STAD) VELO STOD BLOW(APT2) LPIT CONT PRDL EGRA APT1 APT3 APOS ASTP PDT
Page 95
12. Index
A
applicator 57, 59 Applicator 46 APSF 44, 46, 63 ASA 57 Automatic product speed follower Siehe
APSF
C
capacitve label 20 configuration menu 43 Configuration menu 37
D
Direction 45 DIST 49 DTST Siehe Permanent test
E
EP applicator 58 Extended standard menu 37
F
factory values 48
I
interface 48, 51
L
Labelling position 53
M
MACH Siehe Machine type Machine type 45 missing label 45
O
OD control 62 OD-Control 55 Output check 47
P
password 43 permanent test 45 printer 55 product menu 47 Product menu 37 product sensor 14, 30, 32, 33, 40, 43, 44, 47,
45, 53, 60, 75
R
ready 55
S
sensor check 47 serial interface 51, 73 Standard menu 37 Stop position 39, 40, 41, 43, 53
Label counter 49
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