Avery Dennison 230 LH User manual

USER MANUAL
Label Dispenser
ALS
104
Edition 5 4/2010
ALS
104
GB
CONTENTS
1
Please note
1.1
General notes
Label sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Internal Interfaces . . . . . . . . . . . . . . . . . . . . . . .18
Status messages, test functions . . . . . . . . . . . . 18
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Environmental conditions . . . . . . . . . . . . . . . . .18
Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.1.1 Validity and binding effect of this manual . . . . 5
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical status . . . . . . . . . . . . . . . . . . . . . . . . . 5
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Illustrations and descriptions. . . . . . . . . . . . . . 6
Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . 6
Dangers and risk notes . . . . . . . . . . . . . . . . . . . . 6
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Button symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Supplementary information . . . . . . . . . . . . . . . . . 6
1.2
2.1.6 Design models . . . . . . . . . . . . . . . . . . . . . . . 19
Right-handed version . . . . . . . . . . . . . . . . . . . .19
Left-handed version . . . . . . . . . . . . . . . . . . . . . .19
2.2
External control panel . . . . . . . . . . . . . . . . . . . .20
Fixed dispensing edge. . . . . . . . . . . . . . . . . . . .20
Swivelling dispensing edge . . . . . . . . . . . . . . . .20
Spring-loaded dispensing edge . . . . . . . . . . . . .20
Pneumatic dispensing edge . . . . . . . . . . . . . . .21
V-shape dispensing edge . . . . . . . . . . . . . . . . .21
Adjustable dispensing edge holder . . . . . . . . . .21
Outer Diameter control sensor . . . . . . . . . . . . .22
Dust/Splash guard . . . . . . . . . . . . . . . . . . . . . . .22
Additional material guide disk . . . . . . . . . . . . . .22
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Narrow label spring kit . . . . . . . . . . . . . . . . . . . .23
Safety instructions
1.2.1 Information and qualifications . . . . . . . . . . . . . 7
Follow the instructions. . . . . . . . . . . . . . . . . . . . . 7
Keep the product information at hand . . . . . . . . . 7
Ensure the required qualifications are met . . . . . 7
1.2.2 Operational safety of the unit . . . . . . . . . . . . . 8
Proper usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protection against injuries by electrical current . . 8
Protection against injuries by mechanical action. 9
Protection against injuries by chemicals . . . . . . . 9
2.3
1.2.3 Before beginning production . . . . . . . . . . . . . 10
Due diligence of the operating company and the
service technician . . . . . . . . . . . . . . . . . . . . . . . 10
Due diligence of the user. . . . . . . . . . . . . . . . . . 10
Product description
2.1
Overview
Operating modes
2.3.1 Dispensing mode . . . . . . . . . . . . . . . . . . . . . 24
Dispensing speed . . . . . . . . . . . . . . . . . . . . . . .24
Start offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Dispensing manually . . . . . . . . . . . . . . . . . . . . .24
1.2.4 Safety notes on the unit . . . . . . . . . . . . . . . . 11
2
Options
2.3.2 Configuration mode . . . . . . . . . . . . . . . . . . . 25
Function of the double-arrow button . . . . . . . . .25
Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.3.3 Function overview . . . . . . . . . . . . . . . . . . . . 26
2.1.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.4 Function descriptions . . . . . . . . . . . . . . . . . . 27
LABEL SETUP menu . . . . . . . . . . . . . . . . . . . .27
MACHINE SETUP menu . . . . . . . . . . . . . . . . . .27
SERVICE FUNCTION menu . . . . . . . . . . . . . . .27
2.1.2 Control panel. . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating LED. . . . . . . . . . . . . . . . . . . . . . . . . . 14
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4
2.1.3 Connection arrangement . . . . . . . . . . . . . . . 15
Connections on the back of the device . . . . . . . 15
Sensor connections. . . . . . . . . . . . . . . . . . . . . . 15
Inserting label material
2.4.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.2 Inserting a label roll . . . . . . . . . . . . . . . . . . . 29
Removing spent backing paper . . . . . . . . . . . . .29
Removing glue residue . . . . . . . . . . . . . . . . . . .29
Inserting a new label roll . . . . . . . . . . . . . . . . . .29
2.1.4 Mode of operation . . . . . . . . . . . . . . . . . . . . . 16
2.1.5 Technical specifications . . . . . . . . . . . . . . . . 17
Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . 17
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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CONTENTS
2.4.3 Threading the label web . . . . . . . . . . . . . . . . 30
Threading guide . . . . . . . . . . . . . . . . . . . . . . . . 30
Threading the label roll at the dispensing edge. 31
Threading the label roll onto the drive roller . . . 32
Fastening the label roll to the rewinder . . . . . . . 32
5
After operation
5.1
Maintenance and cleaning
5.1.1 Changing fuses . . . . . . . . . . . . . . . . . . . . . . 42
5.1.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . 43
3
Before operation
3.1
Electrical connections
5.1.3 Regular maintenance . . . . . . . . . . . . . . . . . . 43
Removing paper debris . . . . . . . . . . . . . . . . . . .43
3.1.1 Power supply standard machine. . . . . . . . . . 33
Checking the power supply setting . . . . . . . . . . 33
Connecting the power cable.. . . . . . . . . . . . . . . 34
6
Operational failures
6. 1
Erro r messag es
3.1.2 Power supply with dust/splash guard option. 34
6.1.1 Error messaging. . . . . . . . . . . . . . . . . . . . . . 44
3.1.3 Connecting sensors . . . . . . . . . . . . . . . . . . . 34
6.1.2 List of error messages . . . . . . . . . . . . . . . . . 44
3.2
7
Appendix
7.1
EC declarati on of conformity
Mechanical settings
3.2.1 Adjusting the unwinder’s core diameter . . . . 35
3.2.2 Positioning the pressure roller . . . . . . . . . . . 35
3.2.3 Calibrating the label sensor . . . . . . . . . . . . . 36
3.2.4 Setting the dancer arm restoring force . . . . . 36
4
Operation
4.1
Start-up and shutdown
4.1.1 Turning on the unit . . . . . . . . . . . . . . . . . . . . 37
4.1.2 Starting label dispensing. . . . . . . . . . . . . . . . 37
Dispensing with a product sensor . . . . . . . . . . . 37
Dispensing without a product sensor . . . . . . . . 37
4.1.3 Stopping the dispensing process . . . . . . . . . 37
4.2
Configuration and monitoring
4.2.1 Function menu settings. . . . . . . . . . . . . . . . . 38
Label length. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Label stop position . . . . . . . . . . . . . . . . . . . . . . 38
Dispensing speed . . . . . . . . . . . . . . . . . . . . . . . 39
Label position on the product . . . . . . . . . . . . . . 40
4.2.2 Monitoring functions . . . . . . . . . . . . . . . . . . . 41
Missing labels . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Recognising the end of the label roll in
advance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4
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PLEASE NOTE
1.1 GENERAL NOTES
1
P LE AS E NO T E
1.1
GENERAL NOTES
1.1.1 Validity and binding effect of this manual
Contents
Copyright
This technical manual refers exclusively to the ALS 104
Label Dispenser. It is written for the purpose of
ensuring professional usage and calibration of the unit.
Avery Dennison holds all rights to this manual and its
appendices. Reproduction, reprinting or any other
types of duplication, even of portions of this manual,
may only be carried out with express written consent.
Third persons, in particular competitors, should not be
given access to the information in this manual.
Prerequisites for the use and adjustment are the
professional installation and configuration of the unit.
For any technical questions you may have that are not
described in this manual, see:
£ The service manual of the label dispenser
or
£ Request a technician from one of our sales partners.
– Our sales representatives are available to assist
you, particularly with configuring the unit as well as
in the case of malfunctions.
Printed in Germany
Manufacturer
Avery Dennison Deutschland GmbH
Ohmstrasse 3
85386 Eching, Germany
Phone: +49-8165-925-0
Fax: +49-8165-925-231
http://www.machines.averydennison.com
Technical status
Technical status: 10/2008
Software version: 3.21 (front end), 1.84 R01 (drive)
Avery Dennison reserves the right:
– To make modifications to construction parts,
components and software, as well as to employ
comparable components in place of the parts
specified, in keeping with technical advances.
– To modify information in this document.
No commitment will be made to expand these
modifications to include any units delivered earlier.
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PLEASE NOTE
1.1 GENERAL NOTES
1.1.2 Illustrations and descriptions
Signs and symbols
Figures
Various information types are indicated in different
ways within the document in order to simplify
readability and comprehension.
Texts are accompanied by figures where necessary.
Figures are indicated using figure numbers in [square
brackets]. A capital letter after a figure number, for
example [12A], refers to a specific section of the figure.
Generally, the label dispenser shown is an ALS 104
right-handed version. The left-handed version is only
shown where it is necessary to differentiate between
the two.
Sentences starting with an arrow are instructions and
guidelines.
£ Perform the instructions one after another in the
specified order.
The following information begins with a dash:
– Lists
– Mode descriptions
– Descriptions of prior steps
– Prerequisites for following actions
Button symbols
– The buttons of the control panel are depicted as
symbols.
– The symbols are depicted with a ‘+’ (PLUS SIGN)
between them if more than one button is to be
pressed.
+
Dangers and risk notes
Important directions that you must absolutely observe
are particularly emphasized:
Functions
WARNING!
A warning refers to risks that can lead to
serious injury or death! The warning
contains safety measures to protect the
relevant persons.
£ Always follow the instructions.
Functions are displayed in grey in the text with the
following structure, MENU NAME > Function name.
Supplementary information
The expert symbol indicates actions that are
only to be performed by qualified and specially
trained personnel.
CAUTION!
A caution indicates risks that can lead to
property damage or injuries to persons
(minor injuries). The caution note contains
instructions for preventing damages.
£ Always follow the instructions.
The information symbol indicates notes and
recommendations, as well as additional
information.
Equipment:
– Equipment, for example lubricants or
cleaning agents
6
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PLEASE NOTE
1.2 SAFETY INSTRUCTIONS
1.2
SAFETY INSTRUCTIONS
1.2.1 Information and qualifications
Ensure the required qualifications are met
Follow the instructions
£ Ensure that only trained and authorized personnel
operate, configure and service the unit.
£ Only allow qualified and well-trained expert
personnel or service technicians to perform
configurations.
£ The responsibilities with regard to operation,
configuration and maintenance should be clearly
defined and consistently maintained.
WARNING!
Safe and efficient operation of the label
dispenser can only be guaranteed if you
observe all necessary information.
Product liability and warranty claims can
only be asserted if the unit was operated in
accordance with the directions in the
manual.
£ In addition, personnel should also be instructed on
a regular basis in matters of occupational safety and
environmental protection.
£ Before operating the unit, read the
operating instructions and all other notes
carefully.
£ Observe the additional safety and
warning notes on the label dispenser.
£ Only permit competent people to operate
and configure the label dispenser.
Qualification for operation
The instruction of personnel using the unit must ensure
that:
– The operating personnel can use the unit on their
own and safely.
– The operating personnel can remedy small
operational disruptions on their own.
Keep the product information at hand
£ At least two people must be instructed in the unit’s
usage.
£ Enough label material must be provided for testing
and instructional purposes.
With respect to this manual:
£ It should be kept at the location where the
unit is installed and be available to the
operator.
£ It should always be legible.
£ If the unit is sold, the manual should be made
available to the new owner.
Qualifications for configuring
The configuration of the controls requires
qualified expertise:
– Personnel configuring the unit must be
acquainted with the functionality of the label
dispenser.
– Personnel configuring the unit must be
acquainted with the modes of operation
within the facility in which the label dispenser
is integrated.
– The personnel configuring the unit must be
able to use the additional menus properly
and appropriately for specific project
requirements.
£ The safety and warning notes affixed to the
unit itself must be kept clean and legible.
Missing or damaged signs must be replaced.
7
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PLEASE NOTE
1.2 SAFETY INSTRUCTIONS
1.2.2 Operational safety of the unit
Proper usage
WARNING
The unit is not protected against splashing
water in its standard model.
The ALS 104 Label Dispenser is a fully automatic unit
for attaching self-adhesive labels to products or
packaging. The company operating the unit must install
it with suitable equipment to protect operating
personnel from danger; for example, the danger of the
hands or fingers being crushed by reaching in between
the product and the dispensing edge.
£ Keep the unit dry.
£ If liquids have penetrated the unit, switch
it off and disconnect or unplug the power
cable immediately. Inform a service
technician.
WARNING!
Improper usage of the unit can cause
accidents, property damage and production
downtime!
WARNING
The device is only completely disconnected
from the mains if the power cable is
unplugged.
£ Only use the unit in accordance with the
instructions specified in this manual.
£ Do not operate the unit without the
required safeguards.
£ Only configure the unit in accordance
with this manual and with the required
care.
£ Only use original accessories.
£ Do not make any modifications or
alterations to the unit.
£ Repairs to the device may only be
performed by authorised specialists who
are aware of the risks involved.
£ Make sure the power supply socket is
accessible.
£ In case of emergency, switch off the
device and disconnect the power cable.
CAUTION
A too high or low supply voltage can damage
the unit.
£ Only operate the device using the system
voltage indicated on the nameplate.
£ Ensure that the mains voltage set on the
unit is the same voltage as that provided
by the electricity supplier.
Protection against injuries by electrical
current
WARNING!
The machine operates using mains voltage!
Touching live electrical parts may expose
you to hazardous electrical currents and
may lead to burns.
£ Only operate the unit once the housing
has been reassembled properly.
£ Only connect the unit to a properly fitted
power socket that is grounded.
£ Before cleaning, switch off the unit and
remove the power cable from the socket.
£ Only link the unit to devices that fulfil the
SELV (safety extra-low voltage) circuit
requirements specified in EN 60950.
8
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PLEASE NOTE
1.2 SAFETY INSTRUCTIONS
Protection against injuries by mechanical
action
WARNING!
Risk of injury due to moving and rapidly
rotating parts!
– Long hair, loose jewellery, long sleeves,
and so on are not permissible when using
the unit.
£ Sufficient protective clothing must be
worn.
£ Keep moving parts free from
obstructions even when the unit is not
switched on, if there is a chance the
machine might be turned on.
£ Switch off the machine before making
any mechanical settings.
£ Do not wear ties, loose clothing,
jewellery, wrist watches or similar items
on your person when near the operating
unit.
WARNING!
There is a risk that you may get your fingers
or hands crushed on the dispensing edge by
products on the conveyor belt!
£ Never reach between the product and the
dispensing edge while the unit is in
operation or ready for operation.
£ Never reach behind the safety guard or
remove it while the unit is in operation.
Protection against injuries by chemicals
CAUTION!
Operating materials such as cleaning agents
or the solvents in glues can be damaging to
health.
£ Always follow the instructions, use and
safety regulations specified by the
manufacturer!
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PLEASE NOTE
1.2 SAFETY INSTRUCTIONS
1.2.3 Before beginning production
Due diligence of the operating company
and the service technician
Due diligence of the user
£ Check that the safety installations are working
properly.
£ Inspect the machinery for any visible damage.
Report any ascertained defects immediately.
£ Use the required personal protective equipment
correctly, for example, wear a hairnet.
£ Remove any unnecessary materials and objects
from the operating area of the unit.
£ Ensure that only authorised persons are within the
operating range of the machine.
£ Ensure that starting up the machine will not injure
anyone.
£ Ensure that the following prerequisites are fulfilled in
accordance with the service instructions:
– The machine is installed properly and configured in
accordance with the guidelines.
– All required safety mechanisms have been installed.
– The unit has performed at least one successful test
run.
– The unit is connected to the power supply.
£ The users have the required personal protective
equipment, for example, a hairnet. Ensure that the
protective equipment is utilised correctly.
10
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PLEASE NOTE
1.2 SAFETY INSTRUCTIONS
1.2.4 Safety notes on the unit
CAUTION!
Warning notes on the unit represent
important information for the personnel
using it.
£ Do not remove warning notes.
£ Replace any missing or illegible
warnings.
The ‘Pinch Point’ warning [1] note warns you of the
danger posed by the machine’s rotating parts; they can
trap items and draw them in.
! WARNING
Pinch point.
Keep hands clear
of rollers.
A5346
[1]
Left: ‘Pinch Point’ warning. Right: Position of the warning note on the ALS 104. Item number of the label: A5346.
The blue label ‘Read manual’ [2] demands that users
read the unit instructions.
Handbuch lesen!
Read the manual!
Lisez le manuel!
Lea el manual!
Legga il manuale!
[2]
Left: ‘Read manual’ notice. Right: Position of the notice on the ALS 104. Item number of the label: A5331.
11
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PRODUCT DESCRIPTION
2.1 OVERVIEW
2
P RO D U CT D ES CR IP TI ON
2.1
OVERVIEW
2.1.1 Components
C
B
A
D
O
N
E
M
L
F
K
J
G
H
I
[3]
ALS 104 Label Dispenser (right-handed version)
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PRODUCT DESCRIPTION
2.1 OVERVIEW
I Dispensing edge
– Standard: (non-adjustable) L-shaped dispensing
edge
– The following options are available: V-shaped
dispensing edge, adjustable L-shaped dispensing
edge, spring-loaded L-shaped dispensing edge,
pneumatic L-shaped dispensing edge
A Control panel
– For sending commands to the device and for
displaying operating states and error messages.
– An optional external control panel can also be
connected to the device.
B Dispenser
– Dispenser mandrel grasps the label roll.
J Drive roller
– Drives the label material forwards
C Core diameter adapter
– For adjusting the diameter of the dispenser mandrel
to match the core diameter of the label roll.
K
–
–
–
D Adjusting knob
– Turning this in a clockwise direction secures the
label roll on the dispenser.
E Deflection rollers
Pressure mechanism
Presses the pressure roller against the drive roller
Prevents the backing paper from slipping through
Releases automatically once the backing paper has
been drawn around the drive roller
L Tensioning plate
– Keeps the backing paper taut
F Dispensing edge bracket
M Rewinder
– Rolls up the used backing paper
G Label sensor
– Stops the label feed after a label has been
dispensed
N Release button
– Pressing this button reduces the diameter of the
rewinder core.
– Allows the easy removal of the rewound backing
paper
H Pressure roller
– Prints the label once it is stuck to the product
O Dancer arm
– Keeps the backing paper stretched tight evenly
– Arrests the rotation of the material roll if tension
diminishes
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PRODUCT DESCRIPTION
2.1 OVERVIEW
2.1.2 Control panel
Operating LED
Lights up green when the device is switched on.
Status LED
LED
Explanation
On
Dispensing
mode
Off
Configuration
mode
Flashing
Error
[5]
[4]
Meaning of the red status LED
LCD display
– Displays functions, configured values, operating
states and error messages
– What is displayed at any one time depends on the
operating status of the device; these screens are
explained in the section “Operating modes” on
page 24.
Buttons
The button assignments depend on the currently active
operating mode and are described in the section “Operating modes” on page 24.
14
A
B
ON
STATUS
C
Speed
12.2 fix
D
– + – +
Control panel of the ALS 104
A Operating LED
B Status LED
C LCD display
D Buttons
Offset
0.0
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PRODUCT DESCRIPTION
2.1 OVERVIEW
2.1.3 Connection arrangement
Connections on the back of the device
Sensor connections
B
C
D
A
[6]
Connections on the back of the ALS 104:
A Power supply connection
B Signal interface (Sub-D15 port)
C RS232 interface (Sub-D9 port)
D Connection for external control panel (PS/2 port)
[7]
Position of the sensor connections on the ALS 104
C
C
A
LH
E
A
D
D
B
[8]
E
B
Arrangement of the sensor connections (schematic) on the LH (left figure) and RH (right figure) devices.
D Speed sensor (required for automatic speed adaption)
A Product sensor
E Roll diameter sensor
B Label sensor
C Optional: Signal outputs
15
RH
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PRODUCT DESCRIPTION
2.1 OVERVIEW
2.1.4 Mode of operation
In labelling mode, the strip is first pulled from the label
roll around the dancer arm [9A], which consistently
maintains even tension in the label strip. The feed roller
[9D] behind the dispensing edge [9C] draws the strip
across the dispensing plate. The label is unfixed from
the backing paper on the dispensing plate and is
pressed onto the product with the pressure roller [9B].
A
The feed roller drives the label strip forwards the length
of one label and stops until the next product arrives at
the dispensing plate The feed is started by the product
sensor mounted on the conveyor belt. The stop control
provided by the label sensor on the dispensing edge
ensures the feed is halted as soon as a gap is detected
between two labels.
E
The spent backing paper runs from the dispensing
edge around the drive roller [9D], and then over the tensioning plate to be rewound [9E]. The tensioning plate
ensures that rewinding is performed evenly.
D
The entire operation of the label dispenser is controlled
and monitored electronically. If errors occur, the device
controls output an appropriate notification for the operator. If necessary, the labelling operating mode is halted automatically. An electronic signal is output at the
same time. The signal can be fed to an external controller and evaluated.
C
[9]
16
B
The ALS 104 is ready for operation in its idle mode.
A Dancer arm
B Pressure roller
C Dispensing edge
D Drive roller
E Rewinder
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PRODUCT DESCRIPTION
2.1 OVERVIEW
2.1.5 Technical specifications
Power supply
System voltage:
Characteristics
Dispensing speed:
up to 30 m/min
Labelling halt precision 1)
at the peeling edge:
± 0.5 mm
Speed control:
constant speed or automatic speed adaption
using speed sensors
115 V (AC) at 60 Hz power frequency
230 V (AC) at 50 Hz power frequency
Power consumption:
300 VA
Current consumption:
2 A at 115 V system
voltage
1 A at 230 V system
voltage
1) At a speed range of 5 to 30 m/min
Electronics
Labels
Processor:
16 Bit DSP
Label material:
Converted self-adhesive
label material with liner
RAM:
4 kB
Internal rewinding
yes
ROM:
64 kB
Material width
(including backing paper):
10 to 110 mm 2)
Slot for plug-in-cards:
none
Realtime-clock:
none
bis 110 mm 2)
Control panel:
Label width:
Label length:
5 to 600 mm
graphical display with
128 x 32 pixels, 2 lines,
5 buttons
Control panel interface:
RS 422 (Mini DIN 6 connection) for remote control
maximum cable length:
10 m
Service interface:
RS232C, D-Sub 9
Sensor interfaces for
external sensors
(opto-isolated; D-Sub 9
connector, each on a separate 4-pin M12 connector)
Label roll
Winding direction:
Unwinder (outer) Ø:
Rewinder (outer) Ø:
Core (inner) Ø:
face in or face out
up to 300 mm
up to 200 mm
38.1 / 76.2 / 101.6 mm
(1.5 / 3 / 4 ”)
2) Depending on the dispensing edge width.
Label sensor
Distance to peel edge
L-shape dispensing
edge:
V-shape dispensing
edge (fix):
V-shape dispensing
edge (variable):
Transmission sensor:
Label sensor:
Wenglor OPT242-P800
(adjustable by potentiometer) or alternate sensors or signals,
PNP/NPN 3), 24 V
Product sensor:
PNP/NPN 3), 24 V
APSF-Sensor (Rotary
encoder):
single-phase, PNP/
NPN 3)/ P-P, 24 V,
max. 20 kHz
Outer diameter
checking sensor:
PNP/NPN, 24 V
19 mm
77 mm
79-207 mm
Wenglor OPT242-P800
optical, NPN
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PRODUCT DESCRIPTION
2.1 OVERVIEW
PLC outputs:
(connection with D-Sub
15 connector, optional
with 8-pin M12)
3x PNP, 24 V, max.
500 mA/channel, total
permissible output current: 1500 mA
Protection class:
Integration
One insulated relay output, max. 125 mA (NC/
NO), functions parallel to
the PNP outputs (selectable)
Optional output via an
8-pin M12 connector
Mounting points:
side / bottom / rear
Labelling positions:
top / side / bottom
Dispensing edges:
V-shape
L-shape; fixture 90° pivoting, for all L-shape types
(4“ L-shape disp. edge:
material width up to
100 mm only)
3) Selectable by jumper setting
Internal Interfaces
UART for RFID
none
Connector for add motor
driver boards
none
Thermal print head
connectors
none
Certificates
– CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA
– The regulation DIN EN 55022 requires for class A
devices the following text to be printed in the
manual:
Status messages, test functions
Automatic halt, if
Test functions:
IP 21
IP 65 optional (with extras)
„WARNING: This is a class A product. In a domestic
environment this product may cause radio
interference in which case the user may be required
to take adequate measures.“
... the label roll is spent or
no gap was found.
… the maximum allowable number of missing labels has been exceeded.
– The FCC regulation requires the following
information text for class A products:
Automatic diagnostics
check when switched on
„NOTE: This equipment has been tested and found
to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection
against harmful interference when the equipment is
operated in a commercial environment. This
equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in
accordance with the instruction manual, may cause
harmful interference to radio communications.
Operation of this equipment in a residential area is
likely to cause harmful interference in which case
the user will be required to correct the interference
at his own expense“
Dimensions
Height x width x depth: 4)
492 x 488 x 353 mm
Weight:
33 kg
4) Measurements without the dispensing plate bracket and dispensing plate
Environmental conditions
Operating temperature:
5 to 40°C
Humidity:
30 to 85%, (non-condensing)
Noise level (at a distance
of 1 m):
70 dB(A)
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PRODUCT DESCRIPTION
2.1 OVERVIEW
2.1.6 Design models
The ALS 104 Label Dispenser is available in two designs for differing conveyor belt directions.
Right-handed version
A
– The products are transported from left to right [10].
– The dispensing edge is located on the right side.
– Abbreviation: RH
Left-handed version
B
– The products are transported from right to left [11].
– The dispensing edge is located on the left side.
– Abbreviation: LH
The label dispenser operation described in this
manual is based on the right-handed version.
The left-handed version is only taken into account if the explanations or figures of the designs differ significantly.
[10] Right-handed version
A ALS 104
B Product on the conveyor belt
C Labelled product
[11] Left-handed version
19
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PRODUCT DESCRIPTION
2.2 OPTIONS
2.2
OPTIONS
External control panel
– An external control panel can be connected in
addition to the integrated control panel.
– An external control panel is useful if the standard
control panel is inaccessible due to the position in
which the unit is installed.
[12] External control panel
Fixed dispensing edge
– The dispensing edge has a fixed connection to the
brackets.
– To adjust the vertical position, lift/lower the entire
device.
– The slope angle can be adjusted by rotating the
brackets (see the service manual for further details).
[13] Standard dispensing edge
Swivelling dispensing edge
– The position of the dispensing edge can be adjusted
vertically.
– The device need not be moved to adjust the position
of the dispensing edge; the device’s mounting need
not be dismantled.
[14] Swivelling dispensing edge
Spring-loaded dispensing edge
– The dispensing edge is pivoted. A torsion spring in
the dispensing head presses the dispensing edge
downwards and onto the surface of the product.
– Allows compensation for height differences
between the products or on the product surface.
[15] Spring-loaded dispensing edge
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PRODUCT DESCRIPTION
2.2 OPTIONS
Pneumatic dispensing edge
– The dispensing edge is pivoted in the dispensing
head. Compressed air presses the dispensing edge
onto the surface of the product.
– Allows compensation for height differences
between the products or on the product surface.
[16] Pneumatic dispensing edge
V-shape dispensing edge
– An alternative for applications which do not leave
enough space for the standard dispensing edge holder, which juts out to the bottom side.
– Is attached directly to the machine
[17] V-shape dispensing edge
Adjustable dispensing edge holder
Enables a vertical fine adjustment of the dispensing
edge towards the product without moving the machine.
[18] Adjustable dispensing edge holder (pictured red resp. dark
gray)
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PRODUCT DESCRIPTION
2.2 OPTIONS
Outer Diameter control sensor
The outer diameter control sensor (OD sensor) triggers
a warning, if the label roll outer diameter falls below a
certain, adjustable value.
[19] OD sensor (pictured red resp. dark gray)
Dust/Splash guard
Available only for ALS 20X.
Additional sealing of the electrical connections and of
the housing fulfils the requirements of the IP65 protection class [19].
[20] Dust/splash guard of the electrical connections (pictured red
resp. dark gray)
Additional material guide disk
The additional material guide disk [21A] improves the
lateral guiding of the material roll. This option is especially recommended, if very narrow material (< 30 mm
width) is processed.
A
[21] Additional material guide disk (A)
22
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PRODUCT DESCRIPTION
2.2 OPTIONS
Printer
– If necessary, you can mount a hot stamp printer (not
available from Avery Dennison) onto the holder
brackets of the dispensing edge.
– Example of use: Printing consecutive numbers onto
labels.
Narrow label spring kit
Narrow label material may under certain circumstances
tear off or expand in a way which results in poor
labelling precision. In those cases, it is adviseable to
install weaker dancer arm springs.
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PRODUCT DESCRIPTION
2.3 OPERATING MODES
2.3
OPERATING MODES
2.3.1 Dispensing mode
A
– This is the operating mode of the unit when switched
on.
– The display shows the dispensing speed [22A] and
the start offset [22C].
– In dispensing mode, the button assignments are as
shown on the buttons.
– Both settings can be increased (‘+’ button) or
lowered
(‘–’-button) during dispensing operation [22].
– For more information on adjusting the dispensing
operation, see “Function menu settings” on page 38
B
C
ON
STATUS
Offset
0.0
Speed
12.2 fix
– + – +
Dispensing speed
– Setting range:
fix: [5.0…30.0] m/min
var: [0.0…30.0] m/min
– Display fix: The dispensing speed is constant.
– Display var: The dispensing speed adjusts to the
speed of the conveyor belt (‘speed adaption’).
D
E
F
G
[22] Control panel and button functions in dispensing mode.
A Dispensing speed display (here: 12.2 m/min)
B Dispense label button
C Start offset display (here: 0 mm)
D Button to lower dispensing speed
E Button to increase dispensing speed
F Button to lower start offset
G Button to increase start offset
Start offset
– Setting range: [0.0…999.9] mm
– The start offset indicates the distance between the
product sensor and the dispensing edge.
Dispensing manually
To manually trigger the dispensing of individual labels:
£ Press the button
.
– Dispensing speed: As specified in the setting (see
above).
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PRODUCT DESCRIPTION
2.3 OPERATING MODES
2.3.2 Configuration mode
A
Switching to configuration mode:
£ Press the buttons
– Display:
+
.
ON
STATUS
LABEL SETUP
Speed
12.2 fix
– LABEL SETUP is the name of the first menu shown
directly after switching to configuration mode.
– In configuration mode, the button assignments are
as shown below the buttons [23D].
B
Offset
0.0
– + – +
+
C
D
Function of the double-arrow button
LABEL SETUP
To dispense individual labels:
£ Press
button briefly (less than two seconds).
– Dispensing speed: As specified in the configuration;
‘Speed Adaption’ is not active.
MACHINE SETUP
To automatically calibrate the label length:
£ Hold down the button
for a while (more than two
seconds).
– Is equivalent to the function LABEL SETUP > Label Size.
E
SERVICE FUNCTION
[23] Control panel and button functions in configuration mode.
A Button for triggering a dispensing procedure and for
starting the measurement of lengths.
B Display in dispensing mode
C Explanation of buttons in dispensing mode
D Explanation of buttons in configuration mode
E Display indicators in configuration mode
Menus
In ‘Configuration’ mode, the user has access to several
menus providing a fixed sequence of various functions
that can be carried out.
In addition to the LABEL SETUP menu, there are also
the menus MACHINE SETUP and SERVICE
FUNCTION.
Figure [23] shows the button functions for switching
between individual menus and for leaving the
configuration mode.
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PRODUCT DESCRIPTION
2.3 OPERATING MODES
Functions
Every submenu contains functions for setting the unit
controls.
A
Figure [24] shows the buttons functions for changing
the configuration with the example of LABEL SETUP >
Missing Labels.
+
LABEL SETUP
LABEL SETUP
Label Size
3x
LABEL SETUP
Missing Labels
Missing Labels
Alarm after 1
B
Dispense speed
Alarm after 2
C
[24] Button functions when using the LABEL SETUP > Missing
Labels function.
A Button combination for ‘Switching between configuration
and dispensing mode’
B Button to ‘Accept changes’
C Button to ‘Cancel changes’
2.3.3 Function overview
Menus:
LABEL SETUP
MACHINE SETUP
SERVICE FUNCTION 1)
Functions:
Label Size
Factory Settings
Run continuously
Stop Sensor Pos.
Speed Adaption
Machine Type
Product Length
Encoder Resol.
Missing Labels
Encoder Diameter
1) The functions in the SERVICE FUNCTIONS menu are password protected.
[25] Overview of the menus and functions.
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PRODUCT DESCRIPTION
2.3 OPERATING MODES
2.3.4 Function descriptions
MACHINE SETUP menu
LABEL SETUP menu
Function Factory Settings
– Restores factory settings
Function Label Size
– Automatically calibrates the label length
– Display:
Function Speed Adaption
– Settings: On/Off
– On: The dispensing speed is automatically adjusted
to the speed of the conveyor belt; this setting only
functions if a rotary encoder is connected.
– Off: The dispensing speed is constant and is as set
in dispensing mode (see section “Dispensing mode”
on page 24.)
Current Size:
107.7 mm Detect?
– Press
in order to start the calibration; four labels
are dispensed during the calibration.
– Display after the calibration:
Size found:
107.7 mm Accept?
–
Function Encoder Resol.
– Determines the resolution of the rotary encoder.
– Setting range: [10…9999] pulse/revolutions
Press to accept the measured value,
to quit the function and retain the former value.
Function Encoder Diameter
– Determines the diameter of the measuring wheel
installed with the rotary encoder.
– Setting range: [3.2…318.3] mm
– Display:
Function Stop Sensor Pos.:
– Stop sensor position
– Distance between the label sensor (stop sensor)
and the dispensing edge
– This setting determines how far out the labels
protrude over the dispensing edge when the unit is
in its waiting position.
– Setting range: [0.0…999.9] mm
Encoder Diameter
x.x
yy.y var
– The right side (yy.y) shows the speed of the
conveyor belt currently measured. By changing the
measuring wheel diameter, this value can be
adjusted to the actual conveyor speed.
Function Product Length:
– Product length
– Prevents the product sensor from being incorrectly
activated. Once a product has triggered the sensor,
the sensor is locked until the product has passed
under the sensor.
– Setting range: [0.0…999.9] mm
SERVICE FUNCTION menu
Function Run continuously
– A test function that turns on the motor
– To stop motor: Any button
Function Missing Labels:
– Missing labels
– In practice, sometimes labels are missing from the
backing paper. The fault tolerance is defined using
the Missing Labels function.
– Set the number of missing labels that must be
detected before an error message is triggered.
– Setting range: [1…10]
Function Machine Type
– ALS 104 LH: Left-handed unit
– ALS 104 RH: Right-handed unit
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BEFORE OPERATION
2.4 INSERTING LABEL MATERIAL
2.4
INSERTING LABEL MATERIAL
2.4.1 Prerequisites
The label dispenser is turned off at the main switch
– Standard machine: switch set to “O” [26A]
– Machine with dust/splash guard: switch does not
light [27A]
£ Check that the safety installations are working
properly.
£ Inspect the machinery for any visible damage.
Report any ascertained defects immediately.
£ Remove any unnecessary materials and objects
from the operating area of the unit.
£ Ensure that only authorised persons are within the
operating range of the machine.
£ Use the required personal protective equipment
correctly; forexample, wear a hairnet, safety
glasses.
A
[26] Main switch (A) on the housing.
A
[27] Main switch on ALS 104 with dust/splash guard option.
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BEFORE OPERATION
2.4 INSERTING LABEL MATERIAL
2.4.2 Inserting a label roll
WARNING!
Risk of injury due to moving and rapidly
rotating parts!
£ Before inserting the label roll, ensure that
the device is turned off at the main
switch.
£ Do not under any circumstances turn the
device on before the label strip is
threaded in completely.
Removing spent backing paper
Assuming backing paper has gathered on the rewinder
[28A] :
B
£ Press the release button [28C].
– The tensioning mechanism of the rewinder is
slackened.
£ Remove the rewound backing paper.
A
C
Removing glue residue
£
–
–
–
–
If necessary, clean the following components:
Dispensing plate
Deflection rollers
Drive rollers
Pressure roller
[28] A Rewound backing paper
B Backing paper path
C Release button
£ Follow the directions provided in section
“Maintenance and cleaning” on page 42.
Inserting a new label roll
A
£ Push the material roll [29A] onto the unwinder as far
as it will go.
£ Rotate the rotary knob [29B] in a clockwise direction
until the label roll sits tightly.
£ Run the label strip around the dancer arm as shown
in the figure [29C].
– The material strip must run in a slightly different
route when using label rolls with a ‘labels facing
inwards’ winding direction. Insert the roll in such a
way that it unwinds in an anticlockwise direction
(see “Threading guide” on page 30).
B
C
[29] Fasten the label roll to the dispenser (the winding direction
of the roll should be with the labels facing outwards).
29
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BEFORE OPERATION
2.4 INSERTING LABEL MATERIAL
2.4.3 Threading the label web
Threading guide
A
B
[30] Threading guide for ALS 104 with L-shape dispensing edge *.
A Right-handed version
B Left-handed version
A
B
[31] Threading guide for ALS 104 with V-shape dispensing edge *.
A Right-handed version
B Left-handed version
*) Solid line: Path for label rolls with labels facing outwards. Dottet line: differing path for label rolls with labels facing inwards.
30
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BEFORE OPERATION
2.4 INSERTING LABEL MATERIAL
Threading the label roll at the dispensing
edge
£ Unroll around 1 m of label strip and remove the
labels from it.
£ Pass the backing paper around the first deflection
roller [32A] and through the slot in the sensor [32B].
£ Feed the backing paper under the pressure roller
[32C] to the dispensing plate [32D].
£ Feed the backing paper around the dispensing plate
to the second deflection roller [32E].
A
Spring loaded [33] and pneumatic [34] L-Shape dispensing edges:
£ Additionally pass the backing paper between the
two slim deflection rollers at the joint [33A] [34A].
B
C
E
A
D
[32] Path of the label strip near the edge of the dispenser.
A 1st deflection roller
B Label sensor
C Pressure roller
D Dispensing plate
E 2nd deflection roller
A
[34] Path of the label strip at the pneumatic dispensing edge (option).
A
A
[33] Path of the label strip at the spring loaded dispensing edge
(option).
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BEFORE OPERATION
2.4 INSERTING LABEL MATERIAL
Threading the label roll onto the drive
roller
A
£ Open the pressure roller. To do so, rotate the lever
[35D] in a clockwise direction.
£ Feed the backing paper around the deflection roller
[35B], drive roller [35C] and the tensioning plate
[35A].
£ Close the pressure roller. To do so, rotate the lever
anticlockwise until it snaps in noticeably.
D
C
[35] Opening the pressure roller.
[36] Closing the pressure roller.
Fastening the label roll to the rewinder
£ Clamp the backing paper to the rewinder as shown
and tighten it [37].
[37] Fastening the backing paper to the rewinder.
32
B
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BEFORE OPERATION
3.1 ELECTRICAL CONNECTIONS
3
B E FO RE O P ER A TIO N
3.1
ELECTRICAL CONNECTIONS
3.1.1 Power supply standard
machine
WARNING!
This machine operates using mains voltage!
Touching live electrical parts may expose
you to hazardous electrical currents and
may lead to burns.
£ Make sure that the unit is switched off
before connecting the power cable.
£ Only operate the unit with mains voltage
set in the fuse insert.
£ Ensure that the unit is set to receive the
mains voltage supplied by your electricity
provider.
£ Only connect the unit to a grounded
power socket fitted to authorised
standards.
£ The power cable should not be more than
3 m long.
The device is only completely disconnected
from the mains if the power cableis
unplugged. Therefore:
£ Make sure the power supply socket is
accessible.
£ In case of emergency, switch off the
device and disconnect the power cable!
Checking the power supply setting
The ALS 104 is suitable for operation with a
power supply of 230 V (AC) or 115 V (AC).
If you are unsure of what mains voltage your local electricity supplier provides, refer to a qualified service technician.
£ Check whether the right voltage is set in the
display of the fuse insert [38A].
A
Only a qualified service technician is allowed to
change the power supply setting.
You can find further information for performing
this operation in the service manual.
[38] Voltage display on the fuse insert (showing 230 V here).
33
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BEFORE OPERATION
3.1 ELECTRICAL CONNECTIONS
Connecting the power cable.
£ Ensure that power switch [39A] is set to “O” (off).
£ Using the supplied power cable, plug the ALS 104
into a socket connected to the mains supply.
A
B
[39] Power cable (B) plugged in.
3.1.2 Power supply with dust/splash
guard option
ALS 104 labeller with dust/splash guard option
(IP65) may only be connected by qualified service technicians.
3.1.3 Connecting sensors
C
£ Check whether the required sensors are connected
[40] before turning on the ALS 104.
The minimum required sensors:
– Label sensor (installation location: dispensing edge)
– Product sensor (installation location: conveyor belt)
A
You have the option of fitting additional sensors as well:
– Speed sensor (required for speed adaption)
– Outer diameter checking sensor (provides advance
warning of the end of a label roll)
B
You can find further information regarding suitable sensor types, pin assignments, and the
like in the service manual.
[40] Sensor connectors:
A Product sensor
B Label sensor
C Optional: Speed sensor
D Optional: Roll diameter (RD) sensor
34
D
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BEFORE OPERATION
3.2 MECHANICAL SETTINGS
3.2
MECHANICAL SETTINGS
3.2.1 Adjusting the unwinder’s core
diameter
B
Tool:
– 3 mm hexagon (Allen) screwdriver
The unwinder can be adjusted with core adapters [41B]
to fit the inner diameter of the label roll. The adapters
must be fitted and dismantled in different ways
depending on this diameter:
A
– 38.1 mm (1”) core
£ Unscrew the screws [41A] (3 for each adapter) and
remove the adapters.
[41] Core adapter position for a core diameter of 76.2 mm.
– 76.2 mm (3”) core
£ Screw on the adapters, as is shown in Figure [41].
– 101.6 mm (4”) core
£ Screw on the adapters, as is shown in Figure [42].
[42] Core adapter position for a core diameter of 101.6 mm.
3.2.2 Positioning the pressure roller
£ Open the pressure roller [43B]. To do so, rotate the
lever [43C] in a clockwise direction until the roller
snaps up.
£ Release thumb screw [43A].
£ Align the pressure roller over the backing paper so
that it is centred.
£ Close the pressure roller.
£ Screw the thumb screw tight.
B
C
A
[43] Setting the position of the pressure roller (B).
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BEFORE OPERATION
3.2 MECHANICAL SETTINGS
3.2.3 Calibrating the label sensor
Positioning the sensor:
£ Release the thumb screw.
£ Position the sensor along the axle in such a way as
to allow it to register the spaces between the labels.
B
Configuring the sensor:
– The settings required for the sensor depend on the
employed materials. The standard settings are
suitable for many types of label materials.
£ Check whether the LED is lit [44A] when the sensor
is above a space between labels.
– If this is not the case, the sensor must be
configured.
A
[44] Label sensor from Wenglor, model OPT242-P800
£ You should refer to a qualified technician to help
configure the sensor.
– Configuration instructions: See the service
manual.
3.2.4 Setting the dancer arm
restoring force
The unwinder dancer arm is preset in a way, that a wide
range of label materials can be processed whithout having to change the dancer arms restoring force.
Even so, very narrow label material can under certain
circumstances tear off or expand in a way which results
in poor labelling precision. In those cases, the restoring
force must be decreased.
A
Tool:
2.5 mm hex socket screwdriver
£ Turn the adjusting screw [45A] on the dancer arm
left to increase restoring force.
£ Turn the adjusting screw [45A] on the dancer arm
right to decrease restoring force.
[45] Setting screw (A) at the unwinder dancer arm.
A service technician can restore the factory setting, see service manual chap. 6.2.3 section
„Adjusting restoring force of dancer arm“.
If the problem still occurs, although the restoring force
is already set to a minimum, there is the option of building in some weaker springs.
The springs must be built in by a qualified service technician. Instructions can be found in the
service manual, chap. 6.2.3 section „Narrow label kit“.
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OPERATION
4.1 START-UP AND SHUTDOWN
4
4.1
O P E RA TIO N
START-UP AND SHUTDOWN
4.1.1 Turning on the unit
£ Set the main switch [46A] of the unit to ‘I’ (On).
Machine with dust/splash guard option:
– The main switch [47A] lights, if the machine is switched on.
£ Operate the main switch.
A
– Once on, the ALS 104 is in dispensing mode; in
other words, triggering the product sensor will cause
a label to be dispensed.
– More information on the dispensing mode can be
found in the section “Dispensing mode” on page 24.
[46] Main switch (A) of ALS 104.
4.1.2 Starting label dispensing
Dispensing with a product sensor
Once switched on, the ALS 104 is in dispensing mode;
this means that triggering the product sensor will cause
a label to be dispensed.
A
Prerequisites:
– The label length must be specified
– The product sensor must be connected
– The sensor type (PNP/NPN) must be
properly set.
[47] Mains switch (A) of ALS 104 with dust/splash guard option.
Dispensing without a product sensor
It is also possible to trigger the dispensing process
without a product sensor:
£ Press the key
briefly.
4.1.3 Stopping the dispensing
process
£ Set the main switch [46A] of the unit to ‘O’ (Off).
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OPERATION
4.2 CONFIGURATION AND MONITORING
4.2
CONFIGURATION AND MONITORING
4.2.1 Function menu settings
Label length
The label length is calibrated automatically.
Prerequisites:
– Label material is inserted
£ Call up the function LABEL SETUP > Label Size:
Current Size:
0.0 mm
Detect?
£ Press the key
to start the calibration. ALS 104
then dispenses four labels in order to determine
their length:
Size Found:
107.7 mm
Accept?
£ Press the key
to accept the calibrated value, or
press
to retain the old value.
Label stop position
A
Prerequisites:
– The label length must be specified
The next label to be dispensed is halted in the label
stop position. This is useful if the label protrudes over
the dispensing edge somewhat [48].
ALS 104 is pre-configured for use with the
supplied label sensor. If this sensor is
employed, the label stop position setting will
only require minimal correction.
Correcting the default setting:
£ Call up LABEL SETUP > Stop sensor pos..
[48] Label stop position (A)
£ Increase the value to increase the overhang or
lower the value to reduce the overhang.
The value ‘0’ will cause the label to stop directly with its
front edge under the label sensor.
The front edge of the label to be dispensed should be
flush with the dispensing edge:
£ Enter the distance [48A] between the label sensor
and the dispensing edge.
The front edge of the label to be dispensed should
overhang:
£ Add the length of the overhang to the distance
between the label sensor and the dispensing edge.
38
4
OPERATION
4.2 CONFIGURATION AND MONITORING
Dispensing speed
The dispensing speed can be set to a fixed value or can
be configured to automatically adjust to the speed of
the conveyor belt (speed adaption). The second
possibility requires a speed sensor to be connected; it
measures and relays the conveyor speed to the
dispenser.
Configuring a fixed value:
£ Set the speed in dispensing mode with the two left
keys (see “Dispensing mode” on page 24).
Configuring speed adaption:
£ Turn the function on by setting MACHINE SETUP >
Speed Adaption to ‘On’.
£ MACHINE SETUP > Encoder Resol. and
MACHINE SETUP > Encoder Diameter set as
appropriate for the employed speed sensor.
– See the service manual for information on
suitable speed sensors.
39
ALS
104
GB
4
ALS
104
GB
OPERATION
4.2 CONFIGURATION AND MONITORING
Label position on the product
Prerequisites:
– The label length must be specified.
– The label stop position must be set.
The Start Offset is set in dispensing mode with the right
two keys (see “Dispensing mode” on page 24).
– The label should be flush with the front edge of the
product:
£ Enter the distance between the product sensor and
the label sensor [49A].
A
[49] Distance between the product sensor (left) and the label
sensor (right).
– The label should stop at a distance from the front
edge of the product:
£ Increase the start offset [50A] to increase the
distance to the product’s front edge.
A
[50] Distance (A) between the label and the product’s front
40
4
OPERATION
4.2 CONFIGURATION AND MONITORING
4.2.2 Monitoring functions
While in dispensing mode, an electronic control
monitors the following functions:
Missing labels
A label missing from the label roll does not normally
affect the dispensing operation, because the label feed
continues until a label’s edge passes under the label
sensor.
Nonetheless, it can be important that missing labels are
reported. By configuring the function LABEL SETUP
>Missing Labels, you can specify whether an error
message is triggered after one or several missing
labels.
Recognising the end of the label roll in
advance
If the end of the label roll is to be recognised prior to the
last label being dispensed, it is recommended that a
sensor is used to check the outer diameter of the roll.
This sensor, which is available as an extra, is mounted
on the unit in such a way as to trigger an error message
as soon as the roll’s diameter falls short of a specified
value. This diameter can be configured.
41
ALS
104
GB
5
ALS
104
GB
AFTER OPERATION
5.1 MAINTENANCE AND CLEANING
5
A FT ER O P ER A TIO N
5.1
MAINTENANCE AND CLEANING
5.1.1 Changing fuses
WARNING!
The machine operates using mains voltage!
Touching live electrical parts may expose
you to hazardous electrical currents and
may lead to burns.
A
£ Make sure that the machine is switched
off and the power cable is unplugged
before removing the fuse insert.
CAUTION!
Risk of fire, if a wrong fuse type is inserted.
£ Only replace fuses with the type and
rating specified in this manual.
[51] Unlock the fuse insert.
ALS 104 with dust/splash guard: Fuses may
only be replaced by qualified service technicians.
A
£ Turn off the unit. Unplug the power cable.
£ Remove the fuse insert. To do this, press the latch
upwards [51A] and pull out the insert [52A].
– The fuse insert is located directly above the On/Off
switch.
[52] Remove the fuse insert (A).
£ Take the fuses out of the fuse insert.
£ Replace defective fuses.
A
Required fuse type:
– 2x F5AH / 250 V
– The same fuse type is required for 230 V as
for 115 V.
– The fuses must conform to IEC 60127-2/5
(for example, “Wickmann 181 Series”)
[53] Remove (A) fuses.
42
5
AFTER OPERATION
5.1 MAINTENANCE AND CLEANING
5.1.2 Cleaning agents
ALS
104
GB
5.1.3 Regular maintenance
Cleaning agents for rubber rollers:
– Roller cleaner, order number 98925.
If other cleaning agents are used, there is a
chance the rubber may corrode.
The label dispenser is designed to be maintenance-free. However, you should service the unit regularly in order to ensure reliable long-term operating
results.
Cleaning agents for metal deflection rollers:
– Cleaning solvent, alcohol-based solvent,
isopropyl alcohol, spray for removing labels
Depending on operating conditions, you should perform the following at least on a weekly basis:
£ The cleaning and maintenance work described
below.
Cleaning the unit’s housing:
– Commercially available neutral cleaning
liquid
Removing paper debris
£ Wipe the paper residue from the rollers and edges.
£ Clean the sensor lenses with a soft brush or cloth.
WARNING!
Cleaning solvent, alcohol-based solvent and
isopropyl alcohol are highly inflammable!
£ Keep the cleaning agents, as well as any
used cleaning cloths, away from open
flames and other sources of ignition.
£ Do not smoke.
£ Observe the safety instructions on the
container.
CAUTION!
Unsuitable cleaning agents can cause
considerable damage to the unit!
£ Do not use any cleaning agent that could
damage or destroy the resin surface,
labelling, display, nameplates, electrical
components, etc. Observe the
instructions of the cleaning agent
manufacturer.
£ Do not use any abrasive or
plastic-corroding cleaning agents.
£ Do not use any acidic or alkaline
solutions.
43
6
ALS
104
GB
OPERATIONAL FAILURES
6.1 ERROR MESSAGES
6
6.1
O PE RA TI O NA L FA ILU R ES
ERROR MESSAGES
6.1.1 Error messaging
Error messages are displayed as follows:
xxxxxxxxxxxxxxxx
Reset Alarm?
xxxxxxxxxxxxxxxx = Message text
At the same time, a signal is activated at the signal
output of the unit, which can be used to switch on an
external visual or audible signal.
£ Press the key
to reset the error message.
Before considering applying any remedies, check
whether the message appears repeatedly:
£ Turn off the unit and switch it on again after 10
seconds.
– It is important to wait at least 10 seconds before
switching the unit back on again.
6.1.2 List of error messages
No. Message text
Possible cause
Remedy
1
General Alarm
– Motor failure
– Motherboard malfunction
£ Request a service technician
3
Missing Label
– Max. number of missing label was
exceeded
£ Check the label material
4
Material Low
Without a connected roll diameter check:
– The product sensor may have been
mistakenly connected to the socket for
the roll diameter check.
– Internal sensor connection cables may
be mixed up.
With a connected roll diameter check:
– The material roll has fallen short of the
critical diameter.
5
[54]
Unknown Length The function LABEL SETUP > Label Size was
cancelled unsuccessfully.
– No label material inserted.
– Electronic fault.
Overview of numbered error messages.
44
£ Connect the product sensor to the
correct socket.
£ Request a service technician.
£ Prepare to change the material roll.
£ Insert label material.
£ Request a service technician.
7
APPENDIX
7.1 EC DECLARATION OF CONFORMITY
7
7.1
ALS
104
GB
A P PE ND IX
EC DECLARATION OF CONFORMITY
We,
Avery Dennison Deutschland GmbH
Ohmstrasse 3
85386 Eching, Germany
herewith assert that we have designed and built the device described in the following to conform with the basic
safety and health requirements of the relevant EU directives.
Name of the device:
ALS 104
Device type:
Label dispenser
Serial number:
Consists of a sequential number (five-digit) +
date code (YYMM) +
ending (device name): –ALS104
(Example: 040060309–ALS104)
Relevant EU directives:
2004/108/EC (EMC Directive)
2006/95/EC (Low Voltage Directive)
Other applicable, harmonised
norms, in particular:
EN 60 950-1/A11:2004 (Information technology equipment safety)
EN 55 022:2006 class A (Information technology equipment - Radio
disturbance characteristics - Limits and methods of measurement )
EN 61000–6-2: 2005 (Immunity standard for industrial environments)
EN 61000-3-2: 2006 (Limits for harmonic current emissions)
EN 61000-3-3/A2:2005 (Limitation of voltage changes, voltage
fluctuations and flicker)
Year of first CE marking:
2006
Eching, 19. March 2009
Markus Roderer (General Manager)
45
Avery Dennison Deutschland GmbH
Ohmstraße 3
85386 Eching
Germany
Telephone: +49-8165-925-0
http://www.machines.averydennison.com