Avery Dennison ALS 350 Technical data

OPERATING MANUAL
Label Dispenser
ALS
350
450
Article number: A6432, Release 06.2005
ALS
350
450
CONTENTS
1
Please observe the following
1.1
General information . . . . . . . . . . . . . . 6
2.1.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 17
Right-hand version . . . . . . . . . . . . . . . . . . . . 17
Left-hand version . . . . . . . . . . . . . . . . . . . . . 17
1.1.1 Validity and applicability of this manual . . . . . 6
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical State . . . . . . . . . . . . . . . . . . . . . . . . 6
Copyright notice . . . . . . . . . . . . . . . . . . . . . . . 6
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2
2.2.1 Structural elements . . . . . . . . . . . . . . . . . . . 18
2.2.2 Principle of operation . . . . . . . . . . . . . . . . . . 20
2.2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . .
Characteristic values . . . . . . . . . . . . . . . . . .
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient conditions. . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . .
Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical system . . . . . . . . . . . . . . . . . . . . .
Control system . . . . . . . . . . . . . . . . . . . . . . .
Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Conventions and information . . . . . . . . . . . . . 7
Explanation of symbols . . . . . . . . . . . . . . . . . . 7
Warnings concerning dangers and risks. . . . . 7
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Supplemental information . . . . . . . . . . . . . . . . 7
Directional information . . . . . . . . . . . . . . . . . . 8
ALS 350 and ALS 450 . . . . . . . . . . . . . . . . . . 8
1.2
Overview of the ALS 450 . . . . . . . . . 18
Safety instructions . . . . . . . . . . . . . . . 9
22
22
22
22
22
22
22
22
22
2.2.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 23
Right-hand version . . . . . . . . . . . . . . . . . . . . 23
Left-hand version . . . . . . . . . . . . . . . . . . . . . 23
1.2.1 Information and qualifications . . . . . . . . . . . . . 9
Pay attention to the information . . . . . . . . . . . 9
Information must be made available . . . . . . . . 9
Ensure necessary qualifications . . . . . . . . . . . 9
2.3
Options . . . . . . . . . . . . . . . . . . . . . . . 24
Serial interface . . . . . . . . . . . . . . . . . . . . . . .
Roll diameter control . . . . . . . . . . . . . . . . . .
Adjustable dispensing edge . . . . . . . . . . . . .
Spring-loaded dispensing edge . . . . . . . . . .
Pneumatic dispensing edge . . . . . . . . . . . . .
Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water-resistant electronic control unit . . . . .
1.2.2 Machine operating safety . . . . . . . . . . . . . . . 10
Appropriate use. . . . . . . . . . . . . . . . . . . . . . . 10
Protect against injuries that can result from electrical current . . . . . . . . . . . . . . . . . . . . . . . . . 10
Protect against injuries that can result from mechanical actions . . . . . . . . . . . . . . . . . . . . . . 10
Protection against chemical injuries . . . . . . . 10
24
24
24
24
24
24
24
24
1.2.3 Before every production start . . . . . . . . . . . . 11
Operator's obligation and service personal to
exercise care. . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating personnels' obligation to exercise
care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4
2
Equipment description
2.4.2 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1
Overview of the ALS 350 . . . . . . . . . 12
2.5
Operator controls . . . . . . . . . . . . . . . 25
2.4.1 Operator panel . . . . . . . . . . . . . . . . . . . . . . . 25
LED indicator . . . . . . . . . . . . . . . . . . . . . . . . 25
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control system . . . . . . . . . . . . . . . . . 27
2.1.1 Structural elements . . . . . . . . . . . . . . . . . . . . 12
2.5.1 Brief description . . . . . . . . . . . . . . . . . . . . . . 27
2.1.2 Principle of operation . . . . . . . . . . . . . . . . . . 14
2.5.2 Menus for operators and calibration technicians
28
2.1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . 16
Characteristic values. . . . . . . . . . . . . . . . . . . 16
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ambient conditions . . . . . . . . . . . . . . . . . . . . 16
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical system . . . . . . . . . . . . . . . . . . . . . . 16
Control system . . . . . . . . . . . . . . . . . . . . . . . 16
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.3 Monitoring functions . . . . . . . . . . . . . . . . . . .
Dispensing a label to each product . . . . . . .
Label supply . . . . . . . . . . . . . . . . . . . . . . . . .
If errors occur . . . . . . . . . . . . . . . . . . . . . . . .
3
29
29
29
29
3
Prior to operating
3.1
Insert the labelling material – ALS 350.
ALS
350
450
CONTENTS
30
Manually initialise the material . . . . . . . . . . . 47
4.1.2 Labelling. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . .
Start dispensing labels . . . . . . . . . . . . . . . . .
Unwind unit . . . . . . . . . . . . . . . . . . . . . . . . .
Rewind unit . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Insert the label roller . . . . . . . . . . . . . . . . . . . 30
Remove the old backing material . . . . . . . . . 30
Remove adhesive residues. . . . . . . . . . . . . . 30
Insert new label roll . . . . . . . . . . . . . . . . . . . . 31
4.1.3 Stop/end the label dispensing . . . . . . . . . . . 50
3.1.3 Threading the label ribbon . . . . . . . . . . . . . . 32
Overview of the threading path diagram . . . . 32
Thread the label ribbon at the unwind unit . . 33
Guide the label ribbon around the dispensing
edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Thread the label ribbon at the rewind unit. . . 35
3.2
4.1.4 Tandem operation . . . . . . . . . . . . . . . . . . . .
Principle of operation . . . . . . . . . . . . . . . . . .
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . .
Start dispensing labels . . . . . . . . . . . . . . . . .
Reloading label material. . . . . . . . . . . . . . . .
Switching off. . . . . . . . . . . . . . . . . . . . . . . . .
Insert the labelling material – ALS 450
36
4.2
3.2.2 Insert the label roller . . . . . . . . . . . . . . . . . . . 36
Remove the old backing material . . . . . . . . . 36
Remove adhesive residues. . . . . . . . . . . . . . 36
Insert new label roll . . . . . . . . . . . . . . . . . . . . 37
4.2.3 Dispensing speed. . . . . . . . . . . . . . . (VELO)57
Automatic dispensing speed (optional) . . . . 57
4.2.4 Label position on the product
(POS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2.5 Automatic material initialisation . . . . . . (INIT)59
4.2.6 If errors occur . . . . . . . . . . . . . . . . . . . . . . . . 60
Warning messages . . . . . . . . . . . . . . . . . . . 60
Error messages . . . . . . . . . . . . . . . . . . . . . . 60
Mechanical settings . . . . . . . . . . . . . 42
3.3.1 Setting the ribbon guides . . . . . . . . . . . . . . . 42
Operator panel support . . . . . . . . . . . . . . . . . 42
Setting the ribbon guides on the dispenser head
42
Deflection roller on the rewind unit . . . . . . . . 42
4.3
4.3.2 Loading product data banks. . . . . . . . . . . . . 61
Please observe: . . . . . . . . . . . . . . . . . . . . . . 61
Activating product databanks at switch-on. . 62
Activating product databanks after switch-on .
62
3.3.3 Adjust the pressure roller and the braking brush
44
Pressure roller. . . . . . . . . . . . . . . . . . . . . . . . 44
Braking brush . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3.3 Create/save product databank . . . . . . . . . .
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . .
Saving the product databank . . . . . . . . . . . .
Documenting product databanks . . . . . . . . .
3.3.4 Adjust (optional) the position of the dispensing
edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Adjusting vertically . . . . . . . . . . . . . . . . . . . . 45
4.1
Activation and shut-down. . . . . . . . . 46
Product databanks . . . . . . . . . . . . . . 61
4.3.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.2 Adjust pressure roller at the dispensing edge43
Operation
55
55
55
55
4.2.2 Label stop position . . . . . . . . . . . . . . (STOD)56
3.2.3 Threading the label ribbon . . . . . . . . . . . . . . 38
Overview of the threading path diagram . . . . 38
Thread the label ribbon at the unwind unit . . 39
Guide the label ribbon around the dispensing
edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Thread the label ribbon at the rewind unit. . . 41
4
51
51
52
52
53
54
Setting and monitoring . . . . . . . . . . . 55
4.2.1 Settings in the standardmenu . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up menu . . . . . . . . . . . . . . . . . . . . . .
Call up function . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3
48
48
49
50
50
63
63
63
63
4.3.4 Delete the product databank . . . . . . . . . . . . 64
4.4
Settings in the extended menu. . . . . 65
4.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.2 Activating an extended menu. . . . . . . . . . . . 67
Please observe: . . . . . . . . . . . . . . . . . . . . . . 67
Calling up menu . . . . . . . . . . . . . . . . . . . . . . 67
4.1.1 Starting the machine . . . . . . . . . . . . . . . . . . . 46
Automatic material initialisation. . . . . . . . . . . 46
4
ALS
350
450
CONTENTS
4.5.2 Electronic transmission ratio of the RPM transmitter . . . . . . . . . . . . . . . . . . . . . . . . (EGRA)81
Setting the compensation factor. . . . . . . . . . 81
Test the setting. . . . . . . . . . . . . . . . . . . . . . . 81
Call up function . . . . . . . . . . . . . . . . . . . . . . . 67
Exit the extended menu . . . . . . . . . . . . . . . . 67
4.4.3 Position of second label
(POS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.4.4 Position of third label. . . . . . . . . . . . . (POS3)68
4.6
4.4.5 Speed ratio . . . . . . . . . . . . . . . . . . . . (VERT)69
Applicator (optional) . . . . . . . . . . . . . 82
4.6.1 Principle of operation . . . . . . . . . . . . . . . . . . 82
4.4.6 Adjust the label stop sensor (CONT) . . . . . . 70
Technology . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Automatically adjusting the photoelectric sensor
70
Manually adjusting the sensor . . . . . . . . . . . 71
4.6.2 Functions in the extended menu . . . . . . . . . 83
Please observe the following: . . . . . . . . . . . 83
Calling up the extended menu. . . . . . . . . . . 83
Applicator type . . . . . . . . . . . . . . . . . .(APPL)83
EP cylinder dwell time . . . . . . . . . . . . (APT1)84
Blowing time. . . . . . . . . . . . . . . . . . . . (APT2)84
Delay time . . . . . . . . . . . . . . . . . . . . . (APT3)84
Fine tuning of the dwell time . . . . . . . (APT4)85
4.4.7 Label distance. . . . . . . . . . . . . . . . . . . (LPIT)72
Set distance . . . . . . . . . . . . . . . . . . . . . . . . . 72
Check setting . . . . . . . . . . . . . . . . . . . . . . . . 72
4.4.8 Distance from the label stop sensor to the dispensing edge
(E–SS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Set distance . . . . . . . . . . . . . . . . . . . . . . . . . 73
Check setting . . . . . . . . . . . . . . . . . . . . . . . . 74
5
After operation
5.1
Care and cleaning . . . . . . . . . . . . . . 86
4.4.9 Product length . . . . . . . . . . . . . . . . . (PRDL)75
5.1.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . 86
4.4.10 Polarity of the product sensor
(P_S_). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1.2 Regular maintenance . . . . . . . . . . . . . . . . . .
Remove paper waste . . . . . . . . . . . . . . . . . .
Braking brush . . . . . . . . . . . . . . . . . . . . . . . .
Capacitive sensor at the dispenser head . . .
4.4.11 Polarity of the label stop sensor . . . . (S_S_)76
4.4.12 Number of unlabelled products
(MLAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
86
87
87
88
6
Operational malfunctions
4.4.14 Advance print start . . . . . . . . . . . . . . . (PDT)78
6.1
Warning messages. . . . . . . . . . . . . . 89
4.4.15 Printer dwell time . . . . . . . . . . . . . . .(PDWT)78
6.1.1 Please observe: . . . . . . . . . . . . . . . . . . . . . . 89
4.4.16 Tandem operation. . . . . . . . . . . . . . .(TMOD)79
6.1.2 If a problem occurs. . . . . . . . . . . . . . . . . . . . 89
4.4.17 Applicator type . . . . . . . . . . . . . . . . . (APPL)79
6.1.3 Warning messages . . . . . . . . . . . . . . . . . . . 89
4.4.18 EP cylinder dwell time. . . . . . . . . . . . (APT1)79
6.2
4.4.13 Electronic transmission ratio of the RPM transmitter (EGRA) . . . . . . . . . . . . . . . . . . . . . . . . 77
4.4.19 Blowing time . . . . . . . . . . . . . . . . . . . (APT2)79
6.2.1 If a malfunction occurs . . . . . . . . . . . . . . . . . 91
4.4.20 Delay time . . . . . . . . . . . . . . . . . . . . (APT3)79
6.2.2 Error codes. . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.4.21 Fine tuning of the dwell time
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (APT4)79
4.4.22 Delete a product data bank
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (LOAD)79
4.4.23 Create/save product data bank
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAVE)79
4.4.24 Delete a product data bank
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (DEL)79
4.5
Error messages . . . . . . . . . . . . . . . . 91
Automatic dispensing speed (APSF) 80
4.5.1 Principle of operation . . . . . . . . . . . . . . . . . . 80
5
7
Appendix
7.1
Factory settings . . . . . . . . . . . . . . . . 95
7.2
Product databanks . . . . . . . . . . . . . . 97
7.3
EC Declaration of Conformity. . . . . . 99
1
PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
350
450
1
P LE AS E O BS ER V E TH E FO LLO W IN G
1.1
GENERAL INFORMATION
1.1.1 Validity and applicability of this manual
Contents
Copyright notice
The present manual refers exclusively to the ALS 350
and ALS 450 labeller machines. The manual is to be
referred to for correct operation and adjustment of the
machine.
All rights to this operating manual are assigned to Avery
Dennison. Transmission, reprinting or any other means
of reproduction of this manual, whether whole or in part,
are not allowed without prior written permission. Third
parties, in particular competitors, are not to be allowed
access to information derived from this manual.
The prerequisites for operation and adjustment are
proper installation and configuration of the machine.
Printed in Germany
For technical questions which are not addressed in this
operating manual:
£ Observe the instructions contained in the labeller
service guide
or
£ Request assistance from a service technician at our
sales partner.
– The customer service at our sales partner is at your
disposal and particularly helpful with configuration
settings and remedying malfunctions.
Manufacturer
Avery Dennison Deutschland GmbH
Ohmstraße 3
D–85386 Eching
Phone: +49-8165-925-0
Fax: +49-8165-3143
http://www.machines.averydennison.com
Technical State
Technical state as of: 06/2005
Software version: 6.1
Avery Dennison reserves the right to:
– implement modifications of structural parts, components and software as well as to use equivalent
components that keep pace with the current state of
technology in lieu of the specified components.
– change information contained in this manual.
An obligation to extend these modifications to previously
delivered machines is excluded.
6
1
PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
350
450
1.1.2 Conventions and information
Explanation of symbols
Illustrations
In order to facilitate legibility and an overview, the various types of information used herein are categorised
and identified with certain symbols.
When required, text passages are accompanied by
illustrations. The reference to an illustration is indicated
by typesetting the [illustration number] in square brackets. Capital letters following an illustration number, e.g.
[12A], refer to the corresponding position indicated in
the illustration.
In general, the right-hand version of labeller ALS 350 is
depicted in the illustrations. The left-hand version or the
ALS 450 are only depicted if differentiation is necessary.
Sentences that are introduced by an arrow contain procedural instructions.
£ Carry out procedural instructions one after the other
in the prescribed order.
The following information is introduced with a dash:
– List items
– Descriptions of conditions
– Description of previous work steps
– Prerequisites for implementing actions described in
the following passage
Supplemental information
The "Experts" symbol earmarks activities that
only to be performed by knowledgeable and
trained personnel.
Warnings concerning dangers and risks
The information symbol indicates notices and
recommendations as well as additional helpful
information.
Important text passages which must absolutely be followed are particularly marked for special attention:
DANGER!
A danger notice indicates an imminent
hazardous situation which, if not avoided,
could result in death or serious injury of the
personnel!
The notice contains instructions on how to
avoid or prevent the danger(s).
£ The instructions must be followed.
Operating materials:
– Operating materials, e.g. lubricants or
cleaning agents
WARNING!
A warning notice indicates risks which could
result in death or serious injury of the
personnel! The notice contains safety
instructions on how to safeguard possibly
affected personnel.
£ The instructions must be followed.
CAUTION!
A caution notice indicates risks which, if
unheeded, could lead to material damage or
bodily injury (minor injuries). The notice
contains instructions on how to prevent
damage or injury.
£ The instructions must be followed.
7
1
ALS
350
450
PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
Directional information
C
Unless otherwise indicated, the directional information
mentioned in the text refers to the construction of the
right-hand version of Top Labeller. See Figure [1] for
the explanation of directional information.
H
G
ALS 350 and ALS 450
The operation of the two labellers described in this
operating manual is very similar. In general, the righthand version of labeller ALS 350 is described. The lefthand version or the ALS 450 are only discussed if the
descriptions deviate significantly.
In the header of each page, it is annotated whether the
respective page applies to the ALS 350 and ALS 450 or
to only one of the two types.
E
B
A
F
D
[1]
8
Definition of directional information
A Front
B Rear
C Upward
D Downward
E Left
F Right
G Clockwise
H Counter-clockwise
1
PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
1.2
ALS
350
450
SAFETY INSTRUCTIONS
1.2.1 Information and qualifications
Pay attention to the information
Ensure necessary qualifications
£ Only allow the machine to be operated, adjusted
and serviced by instructed and authorised personnel.
£ Adjustment tasks via the expanded menus as well
as programming and administration of product databases are only to be performed by qualified and appropriately trained personnel or the customer
service.
£ The responsibilities for operation, adjustment and
servicing of the machine must be clearly defined
and consistently maintained.
WARNING!
Reliable and safe operation of the labeller is
only guaranteed if all necessary information
is observed!
£ Read this operating manual thoroughly
and observe all notices prior to operation.
£ Observe all additional safety and warning
notices attached to the labeller.
£ Only allow qualified persons to operate
and adjust the labeller.
£ Moreover, personnel are to be regularly instructed
about work safety and environmental protection issues.
Information must be made available
This operating manual
£ is to stored at the machine operating location and
made accessible to the operator.
£ is to maintained in legible condition.
£ is to be made available to the new owner if the machine is sold.
Operator qualifications
Instruction of the operating personnel must ensure:
– that operating personnel can use the machine independently and without posing a danger.
– that operating personnel can remedy minor operational malfunctions themselves.
£ Safety and warning notices attached to the machine
must be kept clean and legible. Missing or damaged
warning labels and plates are to be replaced.
£ Train at least 2 person to operate the machine.
£ Make label materials for test purposes available in
sufficient quantities.
Qualifications for adjustment tasks
Settings in the expanded menus of the control
software require knowledge based on experience:
– The adjustment personnel must be familiar
with how the labeller functions.
– Adjustment personnel must be familiar with
the entire system into which the labeller is integrated.
– Adjustment personnel must be able to correctly apply the functions in the expanded
menu system to appropriately address the
order-specific requirements.
9
1
PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
350
450
1.2.2 Machine operating safety
Appropriate use
Protect against injuries that can result
from mechanical actions
The labeller is a fully automatic machine for the application of self-adhesive labels to products or packages.
The machine is to be equipped by the operation planners with suitable safety devices so as to protect the
operating personnel from possible endangerment –
e.g. pinching or entrapment of body parts due to reaching between product and dispensing edge.
WARNING!
Risk of injury due to moving or rapidly rotating parts!
£ The following regulations always apply:
£ Keep a distance from running machines. Wear
snug-fitting clothing and, if necessary, hair nets.
£ Even when the machine is idle, maintain the area
clear of movable parts if the possibility exists that
the machine could start.
£ Never lay tools or loose parts on the machine if the
possibility exists that the machine could start.
£ Switch off the machine before performing mechanical adjustment tasks.
£ Do not wear ties, loose garments, jewellery, watches or similar articles on the body when in the machine vicinity.
WARNING!
Improper usage of the machine can lead to
accidents, material damage and loss of production!
£ Only operate this machine in accordance
with information contained in this manual.
£ Do not put the machine into operation
without the required safety equipment in
place.
£ Only make adjustments to the machine in
accordance with this manual and with all
due care.
CAUTION!
Danger of bodypart trapping and pinching at
the dispensing edge due to products moving
in the conveyor direction!
£ Never reach between the product and dispensing edge of running or operationready machines.
£ During operation, never remove or defeat
the purpose of protective guards that prevent reaching into the machine.
Protect against injuries that can result
from electrical current
WARNING!
The machine is connected with the mains
supply! Contact with energised components
can result in life-endangering currents
through the body as well as burns.
£ Only put the machine into operation when
installed in a correctly installed housing.
– The housing may only be removed by
trained personnel when the machine is
de-energised.
£ Pull out the mains power connection plug
from the socket before cleaning and
maintenance.
Protection against chemical injuries
CAUTION!
Operational materials such as cleaning
agents or adhesive solvents may pose a
health risk.
£ Rules, work guidelines and safety regulations issued by the manufacturer must
absolutely be followed!
The machine is not protected against
splashing water.
£ Maintain the machine in a dry condition.
£ In case fluids penetrate into the machine
interior, immediately switch off the machine and disconnect or plug out from the
mains power supply. Notify a service
technician.
10
1
PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
350
450
1.2.3 Before every production start
Operator's obligation and service personal
to exercise care
Operating personnels' obligation to exercise care
£ Ensure the following prerequisites correspond to the
information of the operating manual:
– The machine is correctly installed and appropriately
configured for the requirements.
– All necessary safety equipment is installed.
– The machine has successfully completed at least
one test run.
– The machine is connected to the power supply.
£ Verify flawless functioning of the safety equipment.
£ Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
£ Use personal safety gear in accordance with the
regulations, e.g. wear hair nets.
£ Non-required materials and objects are to be removed from the working area of the machine.
£ Make sure that only persons authorised to work on
the machine are within the working area of the machine.
£ Make sure that no one will be placed in a hazardous
situation as a result of the machine startup.
£ The required personal safety gear, e.g. hair nets,
must be provided. Make sure that the safety gear is
used in accordance with the regulations.
11
2
ALS
350
EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
2
E Q UI PM E NT D ES C RI PTI O N
2.1
OVERVIEW OF THE ALS 350
2.1.1 Structural elements
B
C
D
A
E
F
G
H
I
J
P
O
N
M
K
L
[2]
Right-hand version of the ALS 350 Labeller
12
2
EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
ALS
350
A Unwind unit
– The unwinding spindle holds the label roll.
I Mounting brackets
– For securing the machine in the system.
B Guiding rod for unwind unit
– Secures the label roll on the unwinding spindle.
J Operator panel
– Used to enter commands into the machine and to
display operating states and error messages
– If equipped with optional water-resistant electronic
control unit: the operator panel is built into a separate switch cabinet.
C Unwind unit deflection roller
D Drive roller unit of the unwind unit
– Pulls the label ribbon evenly from the label roll and
transports it into the loop space.
K Dispenser head
– Optionally equipped with printer or applicator
E Pressure roller of the unwind unit
– Presses the label ribbon against the drive roller unit.
L Dispensing edge
– The label separates from the backing material here.
F Braking brush
– Allows label ribbon to run smoothly, prevents fluttering.
M Drive roller unit of the label feed
– Pulls the label ribbon incrementally over the dispensing edge. A label is dispensed with each incremental movement.
G Loop space
– Shaft located below the pressure roller and the braking brush.
– In this area the label ribbon forms a loop.
N Label feed pressure roller
– Presses the label ribbon against the drive roller unit.
H Casing
– Houses the control electronics, drive electrical system, main switch, and fuses.
– If equipped with optional water-resistant electronic
control unit: the electronic control unit, drive electrical system, and electrical fuses are built into a separate switch cabinet.
O Rewind unit dancer arm and deflection rollers
– 3 fixed deflection rollers
– A spring-loaded, pivoting dancer arm
P Rewind unit
– An electrically driven rewinding roller takes up the
empty backing material.
– A spreader mechanism secures the backing material
roll.
13
2
ALS
350
EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
2.1.2 Principle of operation
A
B
C
D
I
H
G
F
E
[3]
Labeller ALS 350 operationally ready with label ribbon
14
2
EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
In labelling mode, the drive roller unit [2B] transports
the label ribbon from the unwinding spool [2A]. A loop
is formed in the label ribbon below the pressure roller of
the unwind unit [2C] and the braking brush [2D]. The
feed roller unit [2F] behind the dispenser head [2E]
pulls the ribbon over the dispensing edge. The label
separates from the backing material at the dispensing
edge and is transferred onto the product.
The feed roller unit moves the respective ribbon for a
label and then stops until the next product is transported to the dispensing edge. Label ribbon is continuously
unwound at the unwind unit. The loop acts as a buffer
between the continuously operating unwind unit and
the periodically operating label output. The braking
brushes keep the label ribbon taut.
From the dispensing head, the empty backing material
runs over several deflection rollers [2H] and the springloaded, pivoting dancer arm [2G] to the motor-driven
spreader rewinding unit [2I]. The multiple deflections
with the spring-loaded dancer arm act as a buffer between the label output and the rewind unit. When in
operation, the dancer arm pivots back and forth constantly.
The entire operation of the labeller is electronically controlled and monitored. If a malfunction occurs, the control system sends a corresponding message to the
operator. If necessary, the labelling operation is automatically halted. An electronic signal is issued at the
same time. The signal can be picked up and evaluated
by an external control system.
15
ALS
350
2
ALS
350
EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
2.1.3 Technical data
Characteristic values
Labelling speed:
0.2 m/min to 55 m/min
Labelling performance:
Refer to the service guide
Stop accuracy (at the
dispensing edge):
± 0.5 mm
Unwind unit:
Smooth unwinding spindle
Rewind unit:
Spreader mechanism
Operation:
Programmable, can be set
via the operator panel,
11 data bases available
Speed control:
Casing
Covering for the control
electronics:
Polyurethane (PUR),
10 mm thick
Front plate:
Aluminium, anodized,
15 mm thick
Electrical system
Power consumption:
500 VA
Mains connection
Automatic dispensing
speed, with RPMtransmitter
Nominal voltage:
110 V/120 V/130 V/200 V/
220 V/230 V/240 V 1)
Frequency:
50 Hz / 60 Hz 1)
Type of protection
Labels
Label width
(incl. backing material):
10 mm to 155 mm
Label length
maximum 350 mm
at maximum dispensing speed:
16 mm to 250 mm
maximum 400 mm
Core diameter:
76.2 mm
protected against vertically
falling drops of water, not
protected against sprayed
water
IP54 (optional):
Protected against splashing water and dust layers
Drive system
Label roll
Outer diameter:
IP41:
IP41:
2 stepper motors,
1 AC motor
IP54 (optional):
3 stepper motors
1) Customer options
Ambient conditions
Temperature
Operation:
Storage:
Relative humidity:
Control system
Control electronics:
5 °C to 40 °C
5 °C to 70 °C
30 % to 80 %,
not condensing
Dimensions
IP41:
Integrated
IP54 (optional):
The electronic control unit
and operator panel are
built into a separate switch
cabinet
Options:
Dimensions
Width:
Height:
Depth:
735 mm
795 mm
400 mm
Weight
70 kg
– Serial interface
– Roll diameter control
Emissions
Sound pressure level at
a distance of 1 m:
16
75 db (A)
2
ALS
350
EQUIPMENT DESCRIPTION
2.1 OVERVIEW OF THE ALS 350
2.1.4 Design versions
The ALS 350 labeller is available in 2 different versions,
depending on the direction of the conveyor line:
Right-hand version
– The products are conveyed from left to right [4].
– The dispensing edge is located on the right side.
A
Left-hand version
B
– The products are conveyed from right to left [5].
– The dispensing edge is located on the left side.
Labeller operation is described in these instructions based on the right-hand design version.
The left-hand version is only considered if its
descriptions or illustrations differ significantly.
17
[4]
Right-hand version
A ALS 350 labeller
B Product on conveyor line
C Labelled product
[5]
Left-hand version
C
2
ALS
450
EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
2.2
OVERVIEW OF THE ALS 450
2.2.1 Structural elements
B
C
D
E
A
F
G
H
I
J
K
Q
P
O
N
L
M
[6]
Right-hand version of the ALS 450 Labeller
18
2
EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
ALS
450
J Mounting brackets
– For securing the machine in the system.
A Unwind unit
– The unwinding spindle holds the label roll.
– A spreader mechanism secures the label roll.
K Operator panel
– Used to enter commands into the machine and to
display operating states and error messages
– If equipped with optional water-resistant electronic
control unit: the operator panel is built into a separate switch cabinet.
B Dancer arm of the unwind unit
– Spring-loaded and rotatable
– Assists in the flawless unwinding of the label ribbon
from the unwinding spindle
C Guiding rod for unwind unit
– Secures the label roll on the unwinding spindle.
L Dispenser head
– Optionally equipped with printer or applicator
D Unwind unit deflection roller
M Dispensing edge
– The label separates from the backing material here.
E Drive roller unit of the unwind unit
– Pulls the label ribbon evenly from the label roll and
transports it into the loop space.
N Drive roller unit of the label feed
– Pulls the label ribbon incrementally over the dispensing edge. A label is dispensed with each incremental movement.
F Pressure roller of the unwind unit
– Presses the label ribbon against the drive roller unit.
G Braking brush
– Allows label ribbon to run smoothly, prevents fluttering.
O Label feed pressure roller
– Presses the label ribbon against the drive roller unit.
P Rewind unit dancer arm and deflection rollers
– 3 fixed deflection rollers
– A spring-loaded, pivoting dancer arm
H Loop space
– Shaft located below the pressure roller and the
braking brush.
– In this area the label ribbon forms a loop.
Q Rewind unit
– An electrically driven rewinding roller takes up the
empty backing material.
– A spreader mechanism secures the backing material
roll.
I Casing
– Houses the control electronics, drive electrical system, main switch, and fuses.
– If equipped with optional water-resistant electronic
control unit: the electronic control unit, drive electrical system, and electrical fuses are built into a separate switch cabinet.
19
2
ALS
450
EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
2.2.2 Principle of operation
B
C
A
D
E
J
I
H
G
F
[7]
Labeller ALS 450 operationally ready with label ribbon
20
2
EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
In labelling mode, the drive roller unit [7C] transports
the label ribbon from the unwind mandrel [7A] around
the dancer arm [7B]. The dancer arm keeps the label
ribbon constantly taut and slightly under tension. A loop
is formed in the label ribbon below the pressure roller of
the unwind unit [7D] and the braking brush [7E]. The
feed roller unit [7G] behind the dispenser head [7F]
pulls the ribbon over the dispensing edge. The label
separates from the backing material at the dispensing
edge and is transferred onto the product.
The feed roller unit moves the respective ribbon for a label and then stops until the next product is transported
to the dispensing edge. Label ribbon is continuously
unwound at the unwind unit. The loop acts as a buffer
between the continuously operating unwind unit and
the periodically operating label output. The braking
brushes keep the label ribbon taut.
From the dispensing head, the empty backing material
runs over several deflection rollers [7I] and the springloaded, pivoting dancer arm [7H] to the motor-driven
spreader rewinding unit [7J]. The multiple deflections
with the spring-loaded dancer arm act as a buffer between the label output and the rewind unit. When in operation, the dancer arm pivots back and forth
constantly.
The entire operation of the labeller is electronically controlled and monitored. If a malfunction occurs, the control system sends a corresponding message to the
operator. If necessary, the labelling operation is automatically halted. An electronic signal is issued at the
same time. The signal can be picked up and evaluated
by an external control system.
21
ALS
450
2
ALS
450
EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
2.2.3 Technical data
Characteristic values
Labelling speed:
0.5 m/min to 55 m/min
Labelling performance:
Refer to the service guide
Stop accuracy (at the
dispensing edge):
Casing
Covering for the control- Polyurethane (PUR),
electronics:
10 mm thick
Front plate:
± 0.5 mm
Unwind unit:
Unwinding spindle with
spreader mechanism
Rewind unit:
Spreader mechanism
Power consumption:
Operation:
Programmable, can be set
via the operator panel,
11 data bases available
Mains connection
Speed control:
Electrical system
Automatic dispensing
speed, with RPMtransmitter
110 V/120 V/130 V/200 V/
220 V/230 V/240 V 1)
Frequency:
50 Hz / 60 Hz 1)
Type of protection
10 mm to 230 mm
maximum 350 mm
Label length
at maximum dispensing speed:
16 mm to 250 mm
Label roll
Outer diameter:
Core diameter:
500 VA
Nominal voltage:
IP41:
protected against vertically
falling drops of water, not
protected against sprayed
water
IP54 (optional):
Protected against splashing water and dust layers
Labels
Label width
(incl. backing material):
Aluminium, anodized,
15 mm thick
Drive system
maximum 400 mm
76.2 mm
IP41:
2 stepping motors,
1 AC motor
IP54 (optional):
3 stepping motors
1) Customer options
Ambient conditions
Temperature
Operation:
Storage:
Relative humidity:
Control system
Control electronics:
5 °C to 40 °C
5 °C to 70 °C
30 % to 80 %,
not condensing
Dimensions
IP41:
Integrated
IP54 (optional):
The electronic control unit
and operator panel are built
into a separate switch cabinet
Options:
Dimensions
Width:
Height:
Depth:
735 mm
795 mm
560 mm
Weight
85 kg
– Serial interface
– Roll diameter control
Emissions
Sound pressure level at
a distance of 1 m:
22
75 db (A)
2
ALS
450
EQUIPMENT DESCRIPTION
2.2 OVERVIEW OF THE ALS 450
2.2.4 Design versions
The ALS 450 labeller is available in 2 different versions,
depending on the direction of the conveyor line:
Right-hand version
– The products are conveyed from left to right [8].
– The dispensing edge is located on the right side.
A
Left-hand version
B
– The products are conveyed from right to left [9].
– The dispensing edge is located on the left side.
Labeller operation is described in these instructions based on the right-hand design version. In
general, the labeller ALS 350 (without dancer
arm on the unwind unit) is depicted in the illustrations. The left-hand version and the ALS 450
are only considered if their descriptions or illustrations differ significantly.
23
[8]
Right-hand version
A ALS 450 labeller
B Product on conveyor line
C Labelled product
[9]
Left-hand version
C
2
ALS
350
450
EQUIPMENT DESCRIPTION
2.3 OPTIONS
2.3
OPTIONS
Serial interface
Pneumatic dispensing edge
– Almost all of the setting values can be read out and
modified on an external device, the machine status
can be queried, and the machine can be controlled
via this interface.
– For further information, refer to the Service guide
– The dispensing edge is pivotably mounted onto the
dispenser head. Compressed air presses the dispensing edge downward onto the surface of the
product.
– Enables height differences between the products or
surface characteristics differences to be compensated for.
Roll diameter control
– A sensor at the unwind unit monitors the diameter of
the label roll and, along with it, the supply of labels.
– The sensor sends a signal when the diameter of the
label roll reaches a set value.
– This sensor is required if two labellers are operating
in tandem mode (see chapter Operation – Activation
and shut-down, page 46)
Printer
– Inkjet or heat transfer printer at the dispenser head.
Applicator
If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator.
Various kinds of applicators are available depending on
the customer’s needs.
Adjustable dispensing edge
– The position of the dispenser head can be adjusted
vertically.
– This allows adapting the position of the dispensing
edge to changing products.
– The machine does not have to be moved to adjust
the dispensing edge, the labelling head of the machine does not have to be released.
Water-resistant electronic control unit
– Protected against splashing water as per type of
protection IP54
– The control electronics, drive electrical system,
electrical fuses and operator panel are built into a
separate switch cabinet
– Driven exclusively by stepper motors
– Motors are protected against splashing water
Spring-loaded dispensing edge
– The dispensing edge is pivotably mounted onto the
dispenser head. A torsion spring in the dispenser
head presses the dispensing edge downward onto
the surface of the product.
– Enables height differences between the products or
surface characteristics differences to be compensated for.
24
2
ALS
350
450
EQUIPMENT DESCRIPTION
2.4 OPERATOR CONTROLS
2.4
OPERATOR CONTROLS
2.4.1 Operator panel
A
LED indicator
– Display of functions, setting values, operating
states, error messages, and warning messages
B
If the LED indicator is ON:
– The machine is in labelling mode.
– Each time the product sensor is triggered, a label is
dispensed.
If the LED indicator is OFF:
– Labelling mode is switched off.
C
D
Keys
E
FEED
– When this key is pressed, the machine dispenses a
label.
[10] Operator panel of the ALS 350 (same design as ALS 450 operator panel)
A LED indicator
B FEED key
C PRIOR key
D NEXT key
E ENTER key
PRIOR (previous function)
– Paging through the functions in the menu: to see the
previous function, page upward.
– Within a function: raise the current value, e.g. increase dispensing speed.
NEXT (next function)
– Paging through the functions in the menu: to see the
next function, page downward.
– Within a function: reduce the current value, e.g. decrease dispensing speed.
ENTER
– Activate or switch off labelling mode.
– Call up or end functions.
– Acknowledge error and warning messages.
Depending on the menu and the operating
state of the machine, special key functions are
also available. Where special functions are
available, they are described in the relevant
chapter.
25
2
ALS
350
450
EQUIPMENT DESCRIPTION
2.4 OPERATOR CONTROLS
2.4.2 Main switch
– The main switch [11] is located to the left on the
housing.
– The main switch is used to switch the machine on
and off.
WARNING!
Contact with energised components can result in life-endangering currents through the
body as well as burns. Voltage continues to
be present in the housing even when
switched off.
£ Only put the machine into operation when
installed in a correctly installed housing.
£ Maintain the machine in a dry condition.
A
[11] Main switch on the housing
26
2
ALS
350
450
EQUIPMENT DESCRIPTION
2.5 CONTROL SYSTEM
2.5
CONTROL SYSTEM
2.5.1 Brief description
All of the machine’s functions are electronically
controlled. Using the operator panel, the operators,
calibration technicians, or service personnel have
several options for adapting the machine's functions to
current requirements.
It is also possible to modify the basic machine settings.
These are settings such as the motor’s direction of rotation. These settings are not to be changed in normal
operation. They may only be changed by servicing personnel or the customer service.
The LED indicator gives the operator feedback messages regarding the current operating state of the machine. Error messages or warning messages appear on
the display as necessary.
To give the operator a better overview, the setting options for occasionally changing settings, task-specific
data, databanks, and basic settings are grouped together in menus: The standard menu, extended menu,
product databanks, and configuration menu. The following table provides an overview of the range of functions of the standard menu, extended menu, and
product databanks. The configuration menu is described in the service guide.
Before each operation, the operator must check and
adjust the occasionally changing settings such as the
label position on the product or the dispensing speed.
These settings can simply be input at any time by the
operator at the operator panel.
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and system, and can even cause work-related accidents!
– Only specially trained and instructed personnel may alter the settings in the extended menu or access the product
databanks.
Task-specific data such as label distance or product
length are programmed at the beginning of a job. As a
rule, the settings are not modified as long as the job is
being processed. This data input requires in-depth
knowledge and may only be carried out by trained and
instructed personnel (calibration technicians).
Databanks are available for variable or frequently recurring task settings. The task-specific settings can be
saved in a databank. If the settings are needed again
after a product change, it is not necessary to re-input
the data. You only need to call up the corresponding
databank. In all, 11 databanks are available.
Only calibration technicians may administer the product
databanks.
27
2
ALS
350
450
EQUIPMENT DESCRIPTION
2.5 CONTROL SYSTEM
2.5.2 Menus for operators and calibration technicians
Menu
Standard menu
Extended menu
Product databanks
Functions
ON
ON
ON
OFF
OFF
OFF
INIT
INIT
PD01
VELO
VELO
PD02
STOD
STOD
PD03
POS
POS
PD04
POS 2
PD05
POS 3
PD06
VERT
PD07
CONT
PD08
E–SS
PD09
LPIT
PD10
PRDL
PD11
P_S_
S_S_
MLAB
PDT
PDWT
EGRA
TMOD
APPL
APT1
APT2
APT3
APT4
LOAD
SAVE
DEL
QUIT
Activating a
menu
Main switch + NEXT
PRIOR + NEXT
28
Main switch +
PRIOR
2
ALS
350
450
EQUIPMENT DESCRIPTION
2.5 CONTROL SYSTEM
2.5.3 Monitoring functions
E
During labelling operation, the electronic control system and the sensors monitor the following functions.
Dispensing a label to each product
– A photoelectric sensor (product sensor) sends a signal when a product reaches the dispensing
edge [12B]. The signal from the product sensor triggers the label feed for a single label.
– If individual labels are missing from the label ribbon,
the label feed compensates for this and advances
the label ribbon by one additional label distance (label compensation).
– If label compensation does not take place before the
next start signal of the product sensor, the product
does not get labelled. A warning message appears
at the operator panel.
– If the number of unlabelled products exceeds a certain value, the machine stops.
C
A
D
B
[12] A Label stop sensor
B The product sensor sends a signal when the product has
reached the dispensing edge.
C Label roll on the unwinding spool
D Photoelectric sensor of the optional roll diameter control
E Reflector of the roll diameter control
Label supply
– If no more labels arrive at the label stop
sensor [12A] [13A], the machine stops and sends a
signal to the output to the system controller.
– Roll diameter control (optional) [12D, E]:
If the diameter of the label roll on the unwinding
spool [12C] becomes too small, the control system
sends a warning message and a signal to the output
to the system controller. The diameter at which the
signal will be sent can be set by servicing technicians.
If errors occur
If a malfunction occurs, the control system sends a corresponding message to the operator. If necessary, the
labelling operation is automatically halted. The machine simultaneously sends a signal to the system controller.
A
[13] Backing material with a label under the label stop sensor (A)
29
3
ALS
350
PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
3
P RI O R TO O P ER A TIN G
3.1
INSERT THE LABELLING MATERIAL – ALS 350
3.1.1 Prerequisites
£ Verify flawless functioning of the safety equipment.
£ Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
£ Non-required materials and objects are to be removed from the working area of the machine.
£ Make sure that only persons authorised to work on
the machine are within the working area of the machine.
£ Use required personal safety gear in accordance
with the regulations, e. g. wear hair nets, and protective eye-glasses.
A
[14] Main switch on the housing
– The label dispenser is switched off at the main
[14A] switch.
3.1.2 Insert the label roller
WARNING!
Risk of injury due to moving or rapidly rotating parts!
£ Before inserting the label roller, ensure
that the machine is switched off at the
main switch.
£ Never switch on the machine before the label ribbon has been completely threaded
into position.
A
Remove the old backing material
If backing material remains on the rewinding [15A]
roller:
£ Swing the lever [15C] at the rewinding roller over the
red [15B] point.
– The tension of the rewinding roller spreader mechanism is relieved.
£ Remove the rewound backing material.
B
Remove adhesive residues
£
–
–
–
–
If necessary, clean the following components:
Dispensing edge
Deflection rollers
Drive roller
Rewinding roller
C
[15] Remove the backing material from the rewinding roller
A Old backing material
B Red point on the rewinding roller
C Lever for the spreader mechanism of the rewinding roller
£ Observe the notices in chapter Care and cleaning,
Page 86.
30
3
PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
ALS
350
Insert new label roll
£ Loosen the set-screw at the guiding rod [16A] and
swing the guiding rod to the side.
£ If there is still an old roll core on the unwinding spindle: remove the old roll core.
£ Completely push on the new label roll. Make sure
the assembly is correctly positioned (see next page,
chapter Overview of the threading path diagram):
– Label material with labels positioned on the outside
of ribbon band: loose end to the right
– Label material with labels positioned on the inside of
ribbon band: loose end to the left
A
£ Allow the guiding rod to lightly rest against the label
roll and swing it approximately 1 cm over the unwinding spindle.
£ Tighten the set-screw at the guiding rod.
[16] New label roll on the unwinding spindle with the guiding rod (A)
secured to the side
31
3
PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
3.1.3 Threading the label ribbon
Overview of the threading path diagram
A
B
[17] Threading path diagram for label ribbon with the labels on the outside
A Right-hand version
B Left-hand version
A
B
[18] Threading path diagram for label ribbon with the labels on the inside
A Right-hand version
B Left-hand version
32
ALS
350
3
ALS
350
PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
Thread the label ribbon at the unwind unit
£ Swing up the pressure roller [19A] and the braking
brush [19B].
£ Thread the label ribbon around the deflection
rollers [19C] and drive roller unit [19D].
£ Form a loop after the drive roller unit and guide the
label ribbon over the operator panel support [19E].
£ Swing the pressure roller and web brake back into
position.
– The pressure roller and braking brush click into operating position.
A
B
C
D
E
[19] Guides for the label ribbon in the unwinding section
A Pressure roller
B Braking brush
C Deflection roller
D Drive roller unit
E Operator panel support
33
3
ALS
350
PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
Guide the label ribbon around the dispensing edge
£ Unthread approximately 2 m of label ribbon from the
label roll.
£ Guide the label ribbon around the first deflection
roller [20A] and through the slot in the photoelectric
sensor [20C] [21A].
£ Guide the label ribbon under the pressure roller unit
[20B] to the dispensing edge [20D].
£ Guide the label ribbon around the dispensing edge
to the 2nd deflection roller [20E].
£ Thread the label ribbon around the upper deflection
roller [20F].
F
A
B
C
E
D
[20] Guides for the label ribbon in the dispenser head section
A 1st dispenser head deflection roller
B Pressure roller unit
C Label stop sensor
D Dispensing edge
E 2nd dispenser head deflection roller
F Upper deflection roller
A
[21] A Label stop sensor
34
3
PRIOR TO OPERATING
3.1 INSERT THE LABELLING MATERIAL – ALS 350
ALS
350
Thread the label ribbon at the rewind unit
£ Fold down lower pressure roller [22C].
£ Thread the label ribbon around the deflection rollers, the feed roller unit and the dancer arm as
shown in figure [22].
£ Open the spreader mechanism of the rewinding roller using the lever [22F].
– When the spreader mechanism is open, the red
point on the rewinding roller is not visible.
£ Insert the end of the label ribbon into the slot on the
rewinding roller.
£ Close the spreader mechanism of the rewinding roller using the lever. The red point is now visible.
£ Rotate the rewinding roller counter-clockwise until
the label ribbon is under tension.
£ Swing the pressure roller back into operating position.
F
E
After a label roll is passed through, the backing
material roll rests firmly on the rewinding roller.
The spreader mechanism allows the diameter
of the rewinding roller to be decreased. The
backing material roll can then be easily removed.
£ Only rewind the label ribbon on the rewinding
roller when the spreader mechanism is
closed (red point visible).
£ Do not open the spreader mechanism before
the backing material is removed from the rewinding roller
A
D
C
B
[22] Guides for the label ribbon in the rewind unit section
A Deflection rollers
B Feed roller unit
C Pressure roller (in the open position)
D Dancer arm
E Rewinding roller
F Lever for the spreader mechanism of the rewinding roller
(in the open position)
35
3
ALS
450
PRIOR TO OPERATING
3.2 INSERT THE LABELLING MATERIAL – ALS 450
3.2
INSERT THE LABELLING MATERIAL – ALS 450
3.2.1 Prerequisites
£ Verify flawless functioning of the safety equipment.
£ Check machine for visible damage. Any discovered
deficiency is to be reported immediately.
£ Non-required materials and objects are to be removed from the working area of the machine.
£ Make sure that only persons authorised to work on
the machine are within the working area of the machine.
£ Use required personal safety gear in accordance
with the regulations, e. g. wear hair nets, and protective eye-glasses.
A
[23] Main switch on the housing
– The label dispenser is switched off at the main
[23A] switch.
3.2.2 Insert the label roller
WARNING!
Risk of injury due to moving or rapidly rotating parts!
£ Before inserting the label roller, ensure
that the machine is switched off at the
main switch.
£ Never switch on the machine before the
label ribbon has been completely threaded into position.
A
Remove the old backing material
If backing material remains on the rewinding [24A]
roller:
£ Swing the lever [24C] at the rewinding roller over the
red [24B] point.
– The tension of the rewinding roller spreader mechanism is relieved.
£ Remove the rewound backing material.
B
Remove adhesive residues
£
–
–
–
–
If necessary, clean the following components:
Dispensing edge
Deflection rollers
Drive roller
Rewinding roller
C
[24] Remove the backing material from the rewinding roller
A Old backing material
B Red point on the rewinding roller
C Lever for the spreader mechanism of the rewinding roller
£ Observe the notices in chapter Care and cleaning,
Page 86.
36
3
ALS
450
PRIOR TO OPERATING
3.2 INSERT THE LABELLING MATERIAL – ALS 450
Insert new label roll
£ Loosen the set-screw at the guiding rod [25C] and
swing the guiding rod to the side.
£ Rotate the knurled knob [25B] clockwise, to retract
the chucking wedge [25A] in the unwinding spindle.
£ If there is still an old roll core on the unwinding spindle: remove the old roll core.
A
B
£ Completely push on the new label roll. Make sure
the assembly is correctly positioned (see next page,
chapter Overview of the threading path diagram):
– Label material with labels positioned on the outside
of ribbon band: loose end to the right
– Label material with labels positioned on the inside of
ribbon band: loose end to the left
£ Rotate the knurled knob counter-clockwise to secure the label roll on the unwinding spindle.
C
£ Allow the guiding rod to lightly rest against the label
roll and swing it approximately 1 cm over the unwinding spindle.
£ Tighten the set-screw at the guiding rod.
[25] New label roll on the unwinding spindle, secured to the guiding
rod on the side
A Chucking wedge in the unwinding spindle
B Knurled knob on the unwinding spindle
C Guiding rod
37
3
PRIOR TO OPERATING
3.2 INSERT THE LABELLING MATERIAL – ALS 450
3.2.3 Threading the label ribbon
Overview of the threading path diagram
A
B
[26] Threading path diagram for label ribbon with the labels on the outside
A Right-hand version
B Left-hand version
A
B
[27] Threading path diagram for label ribbon with the labels on the inside
A Right-hand version
B Left-hand version
38
ALS
450
3
ALS
450
PRIOR TO OPERATING
3.2 INSERT THE LABELLING MATERIAL – ALS 450
Thread the label ribbon at the unwind unit
£ Swing up the pressure roller [28A] and the braking
brush [28B].
£ Thread the label ribbon around the deflection
rollers [28D], dancer arm roller [28C] and drive roller
unit [28E].
£ Form a loop after the drive roller unit and guide the
label ribbon over the operator panel support [28F].
£ Swing the pressure roller and web brake back into
position.
– The pressure roller and braking brush click into
operating position.
A
B
C
D
E
F
[28] Guides for the label ribbon in the unwinding section
A Pressure roller
B Braking brush
C Dancer arm
D Deflection roller
E Drive roller unit
F Operator panel support
39
3
ALS
450
PRIOR TO OPERATING
3.2 INSERT THE LABELLING MATERIAL – ALS 450
Guide the label ribbon around the dispensing edge
£ Unthread approximately 2 m of label ribbon from the
label roll.
£ Guide the label ribbon around the first deflection
roller [29A] and through the slot in the photoelectric
sensor [29B] [30A].
£ Guide the label ribbon under the pressure roller unit
[29C] to the dispensing edge [29D].
£ Guide the label ribbon around the dispensing edge
to the 2nd deflection roller [29E].
£ Thread the label ribbon around the upper deflection
roller [29F].
F
A
B
C
E
D
[29] Guides for the label ribbon in the dispenser head section
A 1st dispenser head deflection roller
B Label stop sensor
C Pressure roller unit
D Dispensing edge
E 2nd dispenser head deflection roller
F Upper deflection roller
A
[30] A Label stop sensor
40
3
PRIOR TO OPERATING
3.2 INSERT THE LABELLING MATERIAL – ALS 450
ALS
450
Thread the label ribbon at the rewind unit
£ Fold down lower pressure roller [31C].
£ Thread the label ribbon around the deflection rollers, the feed roller unit and the dancer arm as
shown in figure [31].
£ Open the spreader mechanism of the rewinding roller
using the lever [31F].
– When the spreader mechanism is open, the red
point on the rewinding roller is not visible.
£ Insert the end of the label ribbon into the slot on the
rewinding roller.
£ Close the spreader mechanism of the rewinding roller using the lever. The red point is now visible.
£ Rotate the rewinding roller counter-clockwise until
the label ribbon is under tension.
£ Swing the pressure roller back into operating position.
F
After a label roll is passed through, the backing
material roll rests firmly on the rewinding roller.
The spreader mechanism allows the diameter
of the rewinding roller to be decreased. The
backing material roll can then be easily removed.
£ Only rewind the label ribbon on the rewinding
roller when the spreader mechanism is
closed (red point visible).
£ Do not open the spreader mechanism before
the backing material is removed from the rewinding roller
E
A
D
C
B
[31] Guides for the label ribbon in the rewind unit section
A Deflection rollers
B Feed roller unit
C Pressure roller (in the open position)
D Dancer arm
E Rewinding roller
F Lever for the spreader mechanism of the rewinding roller (in
the open position)
41
3
ALS
350
450
PRIOR TO OPERATING
3.3 MECHANICAL SETTINGS
3.3
MECHANICAL SETTINGS
WARNING!
Risk of injury due to moving or rapidly rotating parts!
£ Before carrying out the mechanical settings, ensure that the machine is
switched off at the main switch.
3.3.1 Setting the ribbon guides
Operator panel support
£ Loosen the knurled thumb screws on the front-facing guide ring [32A].
£ To set the guide ring:
– The label ribbon must run between the two guide
rings with as little play as possible, but it must not be
pinched.
£ Tighten the knurled thumb screws.
Setting the ribbon guides on the dispenser
head
A
£ Loosen the knurled thumb screws on the ribbon
guide [32B] and at the label stop sensor [32C].
£ Adjust the ribbon guide [32B] near the ribbon band
allowing as little play as possible, but it must not be
pinch the band. Tighten the knurled thumb screws.
£ In the same manner, adjust the position of the label
stop sensor [32C] and tighten the knurled thumb
screws.
D
Deflection roller on the rewind unit
£ Slide the guide bushes onto the deflection
rollers [32D] behind the feed drive :
– The label ribbon must not run from the side behind
the feed roller unit.
B
C
[32] Ribbon guides
42
3
ALS
350
450
PRIOR TO OPERATING
3.3 MECHANICAL SETTINGS
3.3.2 Adjust pressure roller at the
dispensing edge
The pressure roller [33A] on the dispensing edge enables the label ribbon to run smoothly around the dispensing edge and ensures that the labels separate
cleanly and in a controlled fashion from the backing
material.
The most favourable positioning of the pressure roller
unit may differ depending on the application.
For information on adjusting the pressure roller unit, the
customer service at our sales partner is at your disposal.
Only if necessary:
£ Loosen the fastening screws [33B].
£ Adjust the pressure roller
£ Tighten the fastening screws.
A
B
[33] A Pressure roller unit
B Fastening screws
43
3
ALS
350
450
PRIOR TO OPERATING
3.3 MECHANICAL SETTINGS
3.3.3 Adjust the pressure roller and the braking brush
C
A
B
[34] A Pressure roller, centrally aligned on the label ribbon
B Setting rings with knurled thumb screws
C Braking brush, centrally aligned on the label ribbon
Pressure roller
Braking brush
Mounting locations of the pressure rollers [34A]:
– On the drive roller unit of the unwind unit
– On the drive roller unit of the label feed
£ Align the braking brush [34C] centrally on the label
ribbon.
£ Loosen the knurled thumb screws on the setting
rings [34B].
£ Raise the pressure roller slightly and centrally align
it on the label ribbon.
£ Secure the pressure roller axially with the setting
rings. Tighten the knurled thumb screws.
44
3
ALS
350
450
PRIOR TO OPERATING
3.3 MECHANICAL SETTINGS
3.3.4 Adjust (optional) the position
of the dispensing edge
D
Adjusting vertically
Coarse adjustment:
£ Open the central lock [35B].
£ Hold the dispenser head firmly and open the lower
lock [35C].
£ Slide the dispenser head to the desired height and
tighten the lock [35C].
A
B
Fine adjustment:
£ Open the upper lock [35A].
£ Rotate the spindle [35D] clockwise to move the dispensing edge downward or rotate the spindle counter-clockwise to move the dispensing edge upward.
£ Tighten the lock [35A]
£ Tighten the central lock [35B].
C
Forrecurring adjustments when products are
changed:
£ Use the scales on the guide columns.
[35] Adjustable dispensing edge (optional)
45
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
4
O P E RA TI ON
4.1
ACTIVATION AND SHUT-DOWN
4.1.1 Starting the machine
Before each use, the control system must be adapted
to the inserted label material. During this, the label distance is detected and the photoelectric sensor at the
dispenser head is adapted to the transparency of the
labels and of the backing material. This process is
called material initialisation.
A
Automatic material initialisation
Initialising material at switch-on:
£ Press and hold the FEED key [37A] and switch on
the machine at the main switch [36A].
– The message AUTO [37B] appears on the operator
panel.
– The machine slowly starts up and dispenses a label.
– The label distance is automatically measured.
– The photoelectric sensor is automatically adapted.
£ Release the FEED key once a label gap [38 arrow]
has passed the photoelectric sensor [38A] at the
dispenser head.
[36] Main switch on the housing
B
A
If the initialisation was successful:
– „ON“ appears on the operator panel.
– When the FEED key is pressed, a label is dispensed.
If the initialisation was unsuccessful:
– The message FAIL appears on the operator panel.
£ Switch off and automatically re-initialise the machine.
[37] Operator panel
A FEED key
B AUTO displayed
or:
£ Manually initialise the material employing
qualified calibration technicians.
A
[38] Initialise the label material
46
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
The machine can also be automatically initialised after switch-on by using the INIT function:
£ In the standard menu, press the NEXT or PRIOR key
until INIT [39] is displayed on the operator panel.
£ Call the INIT function by pressing the ENTER key.
£ Press and hold the FEED key.
– The message AUTO appears on the operator panel.
– The machine slowly starts up and dispenses a label.
£ Release the FEED key once a label gap has passed
the photoelectric sensor at the dispenser head.
[39] INIT display on the operator panel
– If the initialisation was successful, „ON“ appears on
the operator panel.
Manually initialise the material
C
If automatic initialisation is not possible, it does
not generally mean there is a malfunction. Manual initialisation is often required if:
– the proper label stop sensor is not installed.
– transparent labels are used.
– labels with only a slight difference of transparency between label and backing material
are used.
– perforated or otherwise blocked out labels
are used [40].
B
C
A
Only by qualified calibration technicians:
£ Calling up the extended menu.
£ Input the label distance using the LPIT
function
£ Adjust the photoelectric sensor using the
CONT function.
[40] A Label distance
B Photoelectric sensor
C Labels with block outs (perforations)
£ Refer to chapter Operation – Settings in the
extended menu.
47
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
4.1.2 Labelling
Prerequisites
– Label material is inserted.
– Machine is switched on.
– Material is initialised.
If „OFF“ appears on the operator panel:
£ Repeatedly press the NEXT or PRIOR key until
„ON“ [42A] is shown on the display.
[41] ENTER key
If „ON“ appears on the operator panel [42A]:
£ Press the ENTER [41] key.
– The unwinding drive runs for a moment and fills the
loop space with label ribbon [42B].
– The unwinding drive runs for a moment until the
dancer arm points upward at an angle of approx.
30° [42C].
A
– The machine is now ready for operation.
B
If no „ON“ display appears on the operator panel after pressing the NEXT and PRIOR keys:
– The machine is possibly in offline mode or
one of the prerequisites for operation has not
been met.
£ Instruct a qualified and authorised service
technician to carry out the settings in the configuration menu.
– For further information, refer to the service
guide.
C
[42] Operation-ready labeller:
A „ON“ is displayed on the operator panel
B Loop space is filled by the label ribbon
C Dancer arm on the rewinding unit points diagonally upward
48
4
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
ALS
350
450
Start dispensing labels
– The conveyor belt starts up. The first product reaches the product sensor (photoelectric sensor) [43].
– The product sensor sends a start signal.
– The start signal from the product sensor triggers the
dispensing of a label (label feed) using the set values for dispensing speed, label distance, etc.
– The dispensing of labels automatically runs in the
same manner for the following products.
B
A
[43] The product sensor (A) has detected a product (B) at the dispensing edge and sends a start signal.
49
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
Unwind unit
– A loop forms in the loop space as a buffer between
the unwind unit and label dispensing,
ALS 350: [44 arrow], ALS 450: [45 arrow].
– A photoelectric sensor in the loop space monitors
the loop.
– If the loop becomes too large, the control system automatically slows the unwinding speed. The dispensing speed does not change.
– ALS 450: The dancer arm swings approximately into
the centre position [45B].
A
Rewind unit
– The multiple deflections with the spring-loaded
dancer arm act as a buffer between the label output
and the rewind unit. During operation, the dancer
arm swings between the horizontal and its upper
end limit,
ALS 350: [44A], ALS 450: [45A].
– If necessary, the control system automatically slows
the rewinding speed. The dispensing speed is not
affected by this.
[44] ALS 350 in labelling mode
B
4.1.3 Stop/end the label dispensing
£ Press the ENTER key.
– The unwind unit, dispenser drive, and rewinding unit
shut down.
– „OFF“ appears on the operator panel [46].
– Start signals from the product sensor are ignored.
A
[45] ALS 450 in labelling mode
[46] OFF display on the operator panel
50
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
4.1.4 Tandem operation
A
B
[47] Two labellers in tandem arrangement
A The active labeller, label roll comes to its end
B Labeller in standby with full label roll, „LOCK“ appears on the operator panel
Principle of operation
During automatic switch-over from one machine to the
other, the distance between the two machines and their
arrangement are taken into consideration. As a rule,
unlabelled products can be prevented. This guarantees
uninterrupted labelling operation. Reloading periods do
not affect the course of production.
In tandem operation, two labellers are arranged one
behind the other. Only one of the labellers is in operation at a time. The other remains in standby.
If the active labeller reports the end of the label roll, it
shuts down. The other labeller takes over the task of labelling. The shut-down labeller can now be loaded with
label material.
The first machine in the production line is designated as
the master device, the second is designated as the
slave device.
The LED indicators on the operator panels of the two
machines indicate their respective operating states.
– ON on the operator panel of the currently active machine
– LOCK on the operator panel of the machine in
standby
– W__5, if the respective machine has shut down due
to reaching the end of the label roll
In tandem operation, the dispensing speed is automatically adapted to the speed of the conveyor belt (also
see chapter Automatic dispensing speed adjustment).
51
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
Prerequisites
– Both machines are configured and tested for tandem operation and automatic dispensing speed adjustment.
– Label material is inserted, machines are switched
on, material is initialised.
– „OFF“ appears on the operator panels of both machines.
A
On the machine that is to begin labelling first:
£ Press the ENTER key [48B].
– The operator panel of this machine indicates
ON [48A]. This machine is activated.
On the other machine:
£ Press the ENTER key.
– The operator panel of this machine indicates LOCK.
B
Start dispensing labels
[48] Operator panel
A „ON“ LED indicator
B ENTER key
– The conveyor belt starts up. The first product reaches the product sensor [49A] of the activated machine.
– The product sensor sends a start signal.
– The machine with the ON indication starts dispensing labels [49B].
– The machine with the LOCK indication remains in
standby [49C].
B
C
A
[49] Start of the label dispensing in tandem operation:
A The first product has reached the product sensor of the machine that is to begin labelling first.
B The machine with the ON indication starts dispensing labels.
C The machine with the LOCK indication remains in standby.
52
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
Reloading label material
WARNING!
Risk of injury from the running conveyor line
at the workplace! Risk of pinching at the dispensing edge!
£ Before reloading label material, ensure
that the machine in question does not
start up unintentionally. The operator
panel must indicate the W__5 warning
message.
£ Absolutely avoid coming into contact
with the conveyor line and the moving
products.
£ Only join the old and new label ribbons
together in the unwinding section or in
the loop space. Never enter the space
near the dispensing edge.
£ If it is not possible to reload label material
safely: Stop operation (see next page).
On the active machine, the label material runs low [50]:
– The machine stops, even before the end of the label
material reaches the dispensing edge.
– The machine's display changes to W__5.
– The other machine is automatically activated.
– The display of the currently active machine indicates
ON.
A
B
On the idle machine (display W__5):
£ Remove the old roll core from the unwinding spool.
Leave the remainder of the label ribbon on the machine.
£ Insert new label roll.
£ Join the beginning of the label ribbon of the new label roll to the end of the old label ribbon with adhesive.
£ Press the ENTER key.
£ The indication changes to LOCK. The machine is
now in standby
[50] Prerequisites for reloading label material during operation:
A The label roll is empty on the first machine. The machine is
not running. The end of the label material is still in the loop
space. The operator panel indicates W__5.
B The second machine automatically takes over the labelling.
The operator panel indicates ON.
For procedure for changing the label roll, see
section Prior to operating – chapter Insert the
labelling material – ALS 350.
53
4
ALS
350
450
OPERATION
4.1 ACTIVATION AND SHUT-DOWN
Switching off
Switch over the active machine
On the operator panel of the active machine:
£ Press the FEED [51] key.
– The indication on the operator panel changes from
ON to BUSY, until the machine stops.
– The machine switches over to standby. The operator panel indicates LOCK.
– The other machine is activated.
[51] FEED key
Stopping operation
On the operator panel of the active machine:
£ Press the ENTER key.
– The machine stops, the operator panel indicates
OFF.
– The other machine is activated.
On the operator panel of the now active machine:
– The indication on the operator panel changes from
LOCK to ON.
£ Press the ENTER key.
– The machine stops, the operator panel indicates
OFF.
To resume operation:
£ On the machine that is to begin labelling first: press
the ENTER key.
– The operator panel of this machine indicates ON.
£ On the other machine: press the ENTER key.
– The operator panel of this machine indicates LOCK.
– As soon as the product sensor sends a start signal,
the labelling operaton is activated.
If the currently active machine is switched off at
the main switch, while the second machine is in
standby:
– The second machine is automatically activated.
£ Do not interrupt tandem operation using the
main switches.
£ Only actuate the main switch if the operator
panels of the two machines indicate OFF.
54
4
ALS
350
450
OPERATION
4.2 SETTING AND MONITORING
4.2
SETTING AND MONITORING
4.2.1 Settings in the standardmenu
Overview
Function/
Display
Brief description
ON
The machine is ready for operation/activate labelling mode
OFF
End labelling mode
INIT
Automatic material initialisation
VELO
Dispensing speed
STOD
Distance between dispensing edge and leading edge of the label
POS
Distance between leading edge of product and label
[52] Functions in the standard menu
Calling up menu
– The standard menu is automatically started when
the machine is switched on, if it was active before
the last shut-down of the machine.
– If the standard menu does not automatically activate: The machine will switch off and back on when
the NEXT [53B] key is pressed.
A
Call up function
B
– The desired function can be selected by pressing
the NEXT [53B] and PRIOR [53A] keys.
– The function is called up by pressing the
ENTER [53C] key.
– To exit the function, press the ENTER key again.
C
[53] Operator panel in the standard menu
55
4
ALS
350
450
OPERATION
4.2 SETTING AND MONITORING
4.2.2 Label stop position
(STOD)
After the label is output, the feed continues to operate,
until the next label is present at the dispensing edge. To
ensure that the labels separate completely from the dispensing edge, it is advisable to allow the feed to run until the next label projects slightly over the dispensing
edge.
The label stop position is the distance between the
leading edge of the next label and the dispensing edge
[54A]. As a rule, this distance should not be more than
3 mm. The respective optimum setting value depends
on the label material used, the product speed, the surface characteristics of the product, and other factors.
£ For problems during the labelling operation, first
check the label stop position.
£ If necessary, set the label stop position as described
below.
A
£ Switch on the machine at the main switch.
£ In the standard menu, press the NEXT [55A] or
PRIOR [55B] key until STOD [56] is displayed on
the operator panel.
£ Call up the STOD function by pressing the
ENTER [55C] key.
– The distance is shown on the operator panel in mm.
£ Set the desired distance using the NEXT or PRIOR
key .
– Settings are possible in 0.1 mm steps:
Minimum: 0 mm
Maximum: set label distance (LPIT function)
£ Confirm the desired value using the ENTER key and
exit the STOD function.
[54] A Distance between dispensing edge and leading edge of the
label
A
B
[55] Symbols on the operator panel keys
A NEXT key
B PRIOR key
C ENTER key
If the value for the STOD function shown on the
operator panel does not agree with the actual
label stop position, it is possible that the control
system contains an erroneous value for the distance between the photoelectric sensor and the
dispensing edge (E_SS function in the extended menu).
[56] STOD display on the operator panel
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4.2 SETTING AND MONITORING
4.2.3 Dispensing speed
(VELO)
As a rule, the labelling speed must correspond to the
product speed. Depending on the operating conditions,
the labelling speed can also be set somewhat higher in
unique cases.
Prerequisites:
– The label stop position (STOD) is correctly set.
A
£ In the standard menu, press the NEXT [57A] or
PRIOR [57B] key until VELO [58] is displayed on
the operator panel.
£ Call up the VELO function by pressing the
ENTER [57C] key.
– The current speed is displayed on the operator panel in m/min.
£ Change the labelling speed using the NEXT or
PRIOR key.
– Settings are possible in steps of 0.1 m/min:
Minimum: 0.5 m/min
Maximum: 55 m/min
£ Confirm the desired value using the ENTER key and
exit the VELO function.
B
[57] Symbols on the operator panel keys
A NEXT key
B PRIOR key
C ENTER key
[58] VELO display on the operator panel
Test the setting:
£ Remove the pressure roller unit at the dispensing
edge.
£ Start the system and only label one product.
– The labelling speed is too low if the product pulls the
label away from the backing material.
– The labelling speed is too high if the label on the
product has folds in it.
Automatic dispensing speed (optional)
If the automatic dispensing speed (APSF) is activated:
– Only display of the current speed using the VELO
function.
– Manual setting of the dispensing speed is not possible.
– For further information on the APSF function, see
chapter 4 Operation – Automatic dispensing speed
(APSF) Page 80.
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4.2 SETTING AND MONITORING
4.2.4 Label position on the product
(POS)
– Distance between leading edge of the product and
leading edge of the label [59A]
Prerequisites:
– The label stop position (STOD) is correctly set.
– The dispensing speed (VELO) is correctly set.
A
£ In the standard menu, press the NEXT [60A] or
PRIOR [60B] key until POS [61] is displayed on the
operator panel.
£ Call up the POS function by pressing the
ENTER [60C] key.
– The distance is shown on the operator panel in mm.
£ Set the desired distance using the NEXT or PRIOR
key.
– Settings are possible in 0.1 mm steps:
Minimum: 10 mm
Maximum: 999.9 mm
£ Confirm the desired value using the ENTER key and
exit the POS function.
[59] A Value for the POS function
Note: POS actually sets the path that the product follows from the product sensor to the triggering of the labelling. If the product sensor is
located at the level of the dispensing edge, this
is the distance between the leading edge of the
product and the label.
A
B
[60] Symbols on the operator panel keys
A NEXT key
B PRIOR key
C ENTER key
[61] POS display on the operator panel
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4.2 SETTING AND MONITORING
4.2.5 Automatic material initiali-
sation
(INIT)
Also refer to chapter Activation and shut-down.
£ In the standard menu, press the NEXT or PRIOR key
until INIT [62] is displayed on the operator panel.
£ Call the INIT function by pressing the ENTER key.
£ Press and hold the FEED key.
– The message AUTO appears on the operator panel.
– The machine slowly starts up and dispenses a label.
[62] INIT display on the operator panel
£ Release the FEED key once a label gap [63 arrow]
has passed the photoelectric sensor [63A] at the
dispenser head.
If the initialisation was successful:
– „ON“ appears on the operator panel.
– When the FEED key is pressed, a label is dispensed.
A
If the initialisation was unsuccessful:
– The message FAIL appears on the operator panel.
£ Initiate the INIT function again
or:
£ Manually initialise the material employing
qualified calibration technicians.
[63] Initialise the label material
If the FEED key is not pressed down when INIT
is displayed on the operator panel, but only
lightly actuated:
– The values for the label distance setting and
the label stop sensor will be deleted provided
these values are stored in the control unit.
– Continual feed at maximum speed is triggered.
– The continual feed only stops after a malfunction occurs.
£ To prevent operational malfunctions, switch
off the machine at the main switch as soon
as possible.
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4.2 SETTING AND MONITORING
4.2.6 If errors occur
Warning messages
If the machine control system detects a malfunction,
but the labelling operation does not have to be interrupted:
– A warning message appears on the LED-indicator
of the operator panel.
– A warning message is displayed in the format
W_nn:
W stands for warning,
nn is a two-digit numerical code.
– An electronic signal is issued at the same time. The
signal can be further processed by an external control system.
– For an explanation of the warning messages and
notes on fault elimination, see chapter Operational
malfunctions.
[64] Example: The warning message W__4 is displayed on the operator panel
Example [64]:
– The current labelling speed is too high.
– The warning message W__4 appears on the operator panel.
– An electronic signal is sent to the system control.
– The system control issues an additional warning
tone.
Error messages
If the machine control system detects a serious malfunction:
– The labelling operation is automatically halted.
– An error message appears on the LED-indicator of
the operator panel.
– A warning message is displayed in the format E_nn:
E stands for error,
nn is a two-digit numerical code.
– An electronic signal is issued at the same time. The
signal can be further processed by an external control system.
– For an explanation of the error messages and notes
on fault elimination, see chapter Operational malfunctions.
[65] Example: The error message E__6 is displayed on the operator
panel
Example [65]:
– The label ribbon is torn.
– The error message E__6 appears on the operator
panel.
– An electronic signal is sent to the system control.
– The system control issues an additonal warning
tone and stops the conveyor belt.
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4.3 PRODUCT DATABANKS
4.3
PRODUCT DATABANKS
4.3.1 Functions
4.3.2 Loading product data banks
Task-specific settings that do not need to be modified
for daily operation:
Please observe:
– POS
– MLAB
– POS2
– PDT
– POS3
– PDWT
– VELO
– EGRA
– STOD
– VERT
– CONT
– APPL
– E–SS
– APT1
– LPIT
– APT2
– PRDL
– APT3
– P_S_
– APT4
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and system, and can even cause work-related accidents!
– Only qualified and specially trained personnel or the customer service are authorised to access the product
databanks.
– S_S_
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4.3 PRODUCT DATABANKS
Activating product databanks at switch-on
– The menu Product databanks is only available, if at
least one product databank is created.
£ While switching on the machine, press and hold the
PRIOR key.
– The product databank menu is activated.
– The indicator with the last activated product
databank [66] blinks.
£ Repeatedly press the NEXT or PRIOR key until the
desired product databank is shown on the display.
£ Activate the product databank by pressing the
ENTER key.
– Once the label dispensing is started, the settings of
the activated product databank are adopted.
[66] Example: Product databank PD01
The product databank menu is automatically
started when the machine is switched on, if it
was active before the last shut-down of the machine.
If, after the desired product databank is loaded,
the machine is to be operated by personnel
who are not authorised to work in the product
databank menu:
£ Switch off the machine at the main switch.
£ Press and hold the NEXT key and switch the
machine on again at the main switch.
– The standard menu is activated.
Activating product databanks after
switch-on
In the extended menu:
£ Call up the LOAD function.
– The indicator with the last activated product databank [67] blinks.
£ Repeatedly press the NEXT or PRIOR key until the
desired product databank is shown on the display.
£ Activate the desired product databank by pressing
the ENTER key.
– Once the label dispensing is started, the settings of
the activated product databank are adopted.
[67] Example: Product databank PD01
£ Exit the extended menu using QUIT.
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4.3 PRODUCT DATABANKS
4.3.3 Create/save product databank
Prerequisites
Saving the product databank
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and system!
– Only appropriately qualified and authorised personnel may create product databanks.
In the extended menu:
£ Call up the SAVE function.
£ Select the desired product databank using the
NEXT or PRIOR key.
– 11 product databanks are available.
£ Using the ENTER key, save the current settings in
the selected product databank.
£ Exit the extended menu using QUIT.
– Settings in the following functions are updated:
– POS
– MLAB
– POS2
– PDT
– POS3
– PDWT
– VELO
– EGRA 1)
– STOD
– VERT
– CONT
– APPL
– E–SS
– APT1
– LPIT
– APT2
– PRDL
– APT3
– P_S_
– APT4
If the selected product databank already contains
data:
– The question YES? appears on the display.
£ Confirm the query by pressing the ENTER key to
overwrite the selected product databank with the
new data.
Should the product databank not be overwritten:
£ Press the NEXT key until QUIT appears on the display.
£ Press the ENTER key.
– The selected product databank is closed without being saved.
£ Select another product databank to save the current
settings.
– S_S_
Documenting product databanks
1) Setting the EGRA is required when operating the automatic dispensing
speed adjustment APSF
£ Document the contents of the product databanks in
a table. Use the example copy in the appendix.
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4.3 PRODUCT DATABANKS
4.3.4 Delete the product databank
In the extended menu:
£ Call up the DEL function.
£ Select the desired product databank using the
NEXT or PRIOR key.
– Only product databanks that contain data are
shown.
– The indicator with the last activated product databank blinks. This product databank cannot be deleted.
£ Delete the selected product databank by pressing
the ENTER key.
£ Exit the extended menu using QUIT.
If the last activated product databank is deleted:
£ Select another product databank using the LOAD
function.
– The desired product databank can now be deleted
using the DEL function.
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4.4 SETTINGS IN THE EXTENDED MENU
4.4
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SETTINGS IN THE EXTENDED MENU
4.4.1 Overview
Function/display
Brief description
ON
The machine is ready for operation/start dispensing labels
OFF
Stop/end the label dispensing
INIT
Automatic material initialisation
VELO
Dispensing speed
STOD
Distance between dispensing edge and leading edge of the label
POS
Distance between leading edge of product (product sensor) and label
POS 2
Distance between the leading edges of the first and second label on the same product
POS 3
Distance between the leading edges of the second and third label on the same product
VERT
Relationship between the dispensing speed and the conveyor belt speed
CONT
Adjust the label stop sensor
E–SS
Distance between label stop sensor and dispensing edge
LPIT
Label distance
PRDL
Product length
P_S_
Polarity of the product sensor
S_S_
Polarity of the label stop sensor
MLAB
Allowable number of unlabelled products
TMOD
Activate and deactivate tandem operation
LOAD
Load product data bank
SAVE
Create and save a product data bank
DEL
Delete the product databank
QUIT
Exit the extended menu
[68] Functions in the extended menu
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4.4 SETTINGS IN THE EXTENDED MENU
In addition, when using a printer (optional):
PDT
Advance print start
PDWT
Printer dwell time
[69] Additional functions for printers
Additional functions when using an Applicator (optional):
APPL
Set the applicator type used
APT1
Set the dwell time for the EP cylinder
APT2
Dwell time for blowing the label on the product
APT3
Delay of the signal air blow
APT4
Fine tuning of the applicator dwell time in connection with APSF
[70] Additional functions for the applicator
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.2 Activating an extended menu
Please observe:
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and system, and can even cause work-related accidents!
– Only specially trained and instructed
personnel may alter the settings in the
extended menu.
Calling up menu
– To access the extended menu, you must enter a
password.
£ Simultaneously press the NEXT and PRIOR keys.
– CODE appears on the LED display.
£ Enter the password [71].
– The following appears on the LED display for approx. 1 second: * * * *
– The extended menu is active.
[71] Key sequence (password) for the extended menu
Call up function
£ Repeatedly press the NEXT or PRIOR key until the
desired function is shown on the display.
£ Call up the function using the ENTER key.
£ To exit the function, press the ENTER key again.
Exit the extended menu
£ Press the NEXT or PRIOR key until QUIT appears
on the display.
£ Press the ENTER key.
– This exits the extended menu.
– The last active menu is active again.
If the machine is now to be operated by personnel who
are not authorised to work in the extended menu:
£ Ensure that the standard menu is active.
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.3 Position of second label
(POS2)
If the products are to be given two labels:
– Distance between the leading edges of the first and
second label [72A].
A
In the extended menu:
£ Call up the POS2 function.
£ Set the desired distance.
– Settings are possible in 0.1 mm steps:
minimum label length,
maximum 999.9 mm
– POS2 is not active if the value is set to 0.
£ Confirm the setting value using the ENTER key and
exit the function.
[72] A Position of second label: Distance between the leading edges
of the first and second label
4.4.4 Position of third label
(POS3)
If the products are to be given three labels:
– Distance between the leading edges of the second
and third label [73A].
In the extended menu:
£ Call up the POS3 function.
£ Set the desired distance.
– Settings are possible in 0.1 mm steps:
minimum label length,
maximum 999.9 mm
– POS3 is not active if the value is set to 0.
£ Confirm the setting value using the ENTER key and
exit the function.
A
[73] A Position of third label: Distance between the leading edges of
the second and third label
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.5 Speed ratio
(VERT)
– Relationship between the dispensing speed and the
conveyor belt speed
Example [74]: Circumferential labelling of a round product. The product simultaneously makes a linear movement and a rotational movement.
In the extended menu:
£ Call up the VERT function.
– The preset is 100 (corresponds to a ratio of 1:1)
£ Set the desired value.
– Possible settings: 80 to 1000 (corresponds to 0.8:1
to 10:1)
£ Confirm the value using the ENTER key and exit
the VERT function.
A
Example [74]:
– The rotational speed [A] is twice as great as the linear speed of the product [B].
– The dispensing speed must roughly correspond to
the rotational speed.
£ Set the setting for VERT to 200 (ratio 2:1).
B
[74] Example: The product simultaneously moves from left to right
and rotates about its axis
A Rotational speed
B Linear speed (conveyor belt speed)
£ If necessary, use the fine adjustment.
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4.4 SETTINGS IN THE EXTENDED MENU
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4.4.6 Adjust the label stop sensor (CONT)
Technology
Automatically adjusting the photoelectric
sensor
Automatic and manual adjustment
£ Press and hold the FEED key and switch on the machine at the main switch.
– The message AUTO appears on the operator panel.
The sensitivity of the label stop sensor must be adjusted to match the transparency of the labels and the
backing material. In most applications, it is possible to
allow the sensitivity of the sensor to be adjusted automatically.
or:
£ When the machine is switched on, call up the INIT
function.
£ Press and hold the FEED key.
When using labels with only a slight difference in the
transparency of the label and the backing material, perforated labels or labels with block outs:
£ Manually adjust the sensors as described below.
–
–
–
£
Non-standard photoelectric sensors
In series production, the labeller is equipped with a
photoelectric sensor manufactured by Wenglor.
The machine slowly starts up and dispenses a label.
The label distance is automatically measured.
The photoelectric sensor is adjusted.
Release the FEED key once a label gap has passed
the photoelectric sensor at the dispenser head.
If the adjustment (measurement) was successful:
– "ON" appears on the operator panel.
When using transparent labels or labels with a very
slight difference in the transparency of the label and the
backing material:
– It is possible that the gap between two labels will not
be detected. Instead of just one label, two or more
labels might be dispensed.
– Use of a mechanical or capacitive sensor is recommended.
– A mechanical sensor is only of limited use at high
dispensing speeds.
If the adjustment (measurement) was not successful:
– The message FAIL appears on the operator panel.
£ Manually adjust the sensor.
When using a non-series production photoelectric sensor:
£ Reduce the setting value for CONT to NONE.
– For information on connecting a mechanical or capacitive sensor, see the service guide.
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4.4 SETTINGS IN THE EXTENDED MENU
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Manually adjusting the sensor
In the extended menu:
£ Call up the CONT function.
£ Insert the backing material without a label under the
photoelectric sensor.
£ Press the PRIOR key until the yellow LED on the
photoelectric sensor [75A] illuminates.
£ Press the NEXT key in stages until the yellow LED
extinguishes again.
£ Make note of the value displayed when the LED
extinguishes: Value of the backing material.
A
£ Insert the backing material with a label under the
photoelectric sensor.
– The LED illuminates.
£ Press the NEXT key until the LED extinguishes.
£ Make note of the value displayed when the LED
extinguishes: Value of the label.
If the LED does not extinguish even at the lowest
value 1:
£ Write down 1 as the value of the label.
[75] Backing material with a label under the label stop sensor;
LED (A) illuminates.
£ Calculating the setting value for CONT:
£ Enter the calculated setting value using the NEXT or
PRIOR key.
£ Confirm the setting value using the ENTER key and
exit the function.
Test the setting:
£ Pull the label ribbon through under the label stop
sensor.
– The LED illuminates, if a label is under the photoelectric sensor [75].
– The LED does not illuminate, if only backing material
is under the photoelectric sensor.
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.7 Label distance
(LPIT)
The label distance is defined as [76]:
Label distance = label length + gap
The shape of the labels or reflective surfaces can
cause a false signal to be sent from the label stop sensor. In such a case, the label distance must be manually set.
B
Set distance
C
A
In the extended menu:
£ Call up the LPIT function.
£ Set the desired distance.
– Settings are possible in 0.1 mm steps:
Minimum: 5 mm
Maximum: 350 mm 1)
£ Confirm the value using the ENTER key and exit the
function.
[76] A Label distance
B Label length
C Gap
£ Check setting.
Check setting
£ Press the FEED key.
If the setting is correct:
– A single label is dispensed at a constant dispensing
speed. The label completely separates from the
backing material and no wrinkling occurs.
If the setting value for LPIT is too large:
– 2 labels are dispensed.
If the setting value for LPIT is too small:
– A single label is dispensed.
– Because the value for LPIT is too small, the control
unit prematurely anticipates a signal from the label
stop sensor. The missing signal triggers automatic
label compensation. This error is indicated if:
– The dispensing speed is excessively fast at
the trailing edge of the label.
– If a printer is connected, the device will print
more than once.
1) Possible at reduced dispensing speeds (up to 999 mm); Refer to the service guide.
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.8 Distance from the label stop
sensor to the dispensing edge
(E–SS)
– Correct specification of the distance between the label stop sensor and the dispensing edge is a prerequisite for setting the label stop position (STOD).
A
Set distance
£ Adjust the distance between the label stop sensor
and dispensing edge Round the measured value up
to a whole number value in mm.
In the extended menu:
£ Call up the E–SS function.
£ Input the distance value.
– Settings are possible in 1 mm steps:
Minimum: 12 mm
Maximum: 1000 mm
– A maximum of 15 labels can be located between the
photoelectric sensor and the dispensing edge.
£ Confirm the value using the ENTER key and exit the
function.
[77] A Distance between the label stop sensor and dispensing edge
£ Check setting (see next page).
The minimum setting depends on the dispensing speed.
– The greater the dispensing speed, the greater the minimum distance.
– If the minimum distance is not maintained,
the warning message W__7 appears.
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Check setting
£ Call up the STOD function.
£ Set the value for STOD to „0“.
£ Confirm the value using the ENTER key and exit the
function.
£ Press the FEED key.
– A label is dispensed.
– The leading edge of the next label should rest exactly
on the dispensing edge [78].
£ Remove a single label from in front of the
sensor [79].
£ Press the FEED key.
– A label is dispensed [80A].
– The gap on the label ribbon should be automatically
compensated for [80B].
– The leading edge of the following label should rest
exactly on the dispensing edge [80C].
[78] The leading edge of the following label should rest on the dispensing edge
After the check:
– Check the label stop position (STOD); refer to
Page 55.
[79] Remove a single label from in front of the sensor
A
B
C
[80] After pressing the FEED key:
A A label is dispensed
B The gap on the label ribbon should be automatically compensated for
C The feed stops, the leading edge of the following label should
rest on the dispensing edge
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.9 Product length
(PRDL)
A start signal can be prematurely triggered by the
shape of the product or reflective surfaces. In such a
case, the product length must be manually set.
Example [81]:
If the product [D] reaches the product sensor [C], a start
signal is sent and the machine dispenses a label. The
recesses in the product trigger additional start signals;
without the PRDL function, the product would be labelled several times. With the product length [A] set in
the PRDL function, the machine ignores all start signals
until the product has passed the dispenser head.
B
A
C
In the extended menu:
£ Call up the PRDL function.
£ Set the product length.
– Settings are possible in 1 mm steps:
Minimum: 5 mm
Maximum: 999 mm
£ Confirm the value using the ENTER key and exit the
function.
D
[81] A
B
C
D
To set the product length the same as the label distance:
£ Set the value for PRDL to less than 5.
– The message AUTO appears on the operator panel.
– The control system automatically sets the value for
PRDL to the value of the label distance (LPIT).
75
Product length
Label
Product sensor
Product with recesses (arrows)
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4.4.10 Polarity of the product sensor
(P_S_)
The product sensor can optionally send the start signal,
if
– the leading edge of the product passes the
sensor [82A].
– the trailing edge of the product passes the
sensor [82B].
In the extended menu:
£ Call up the P_S_ function.
£ Set the desired polarity.
– Set the LEDG: Triggered by leading edge
– Set the TEDG: Triggered by the trailing edge
£ Confirm the setting using the ENTER key and exit
the function.
A
B
[82] Examples for different polarities of the product sensor:
A The sensor sends a signal at the product’s leading edge
(LEDG)
B The sensor sends a signal at the product’s trailing edge
(TEDG)
4.4.11 Polarity of the label stop
sensor
(S_S_)
The label stop sensor can optionally send the signal, if
– the leading edge of the label passes the
sensor [82A] (standard setting, with automatic label
compensation).
– the trailing edge of the label passes the
sensor [82B] (without automatic label compensation).
A
The function also allows the use of photoelectric sensors with different polarities.
In the extended menu:
£ Call up the S_S_ function.
£ Set the desired polarity.
– Set the LEDG: Triggered by leading edge
– Set the TEDG: Triggered by the trailing edge
£ Confirm the setting using the ENTER key and exit
the function.
B
[83] Examples for different polarities of the label stop sensor:
A The sensor sends a signal at the label’s leading edge (LEDG)
B The sensor sends a signal at the label’s trailing edge (TEDG)
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.12 Number of unlabelled products
(MLAB)
If products do not get labelled, the operator receives
the warning message W_0 at the operator panel. If too
many products in a row do not get labelled, the machine
stops. The error message E_11 appears at the operator panel. Using the MLAB function, you can determine
how many products in a row are allowed to be unlabelled before the machine stops.
Example [84]:
MLAB is set to value 2. The machine stops after three
products in a row are not labelled. The error message
E__11 appears on the operator panel.
In the extended menu:
£ Call up the MLAB function.
£ Set the desired value.
– Possible settings: 0 ... 10 products
£ Confirm the setting using the ENTER key and exit
the MLAB function.
[84] Three products in a row were not labelled.
4.4.13 Electronic transmission ratio
of the RPM transmitter (EGRA)
– Compensation factor for RPM transmitter when operating with automatic dispensing speed adjustment
– Refer to Chapter Automatic dispensing speed
(APSF), Page 80.
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4.4 SETTINGS IN THE EXTENDED MENU
4.4.14 Advance print start
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(PDT)
When using a printer (optional):
The printing process can be started even in the final
phase of the label feed. In so doing, the printer stamp
is already moving toward the label ribbon, even before
the label has come to a standstill - this shortens the
printing process.
Using the PDT function, you can determine when (after
how many motor strokes before label stop) the printing
process will be started.
In the extended menu:
£ Call up the PDT function.
£ Set the desired value.
– Possible settings: 0 ... 50 motor strokes
– For the setting 0000, the label stop and printer start
coincide.
£ Confirm the setting using the ENTER key and exit
the function.
[85] The printing process starts while the label feed is still transporting the next label.
The printer stamp is blocking the label feed.
– The printer stamp should first contact the label ribbon only after the label has come to a
standstill.
£ If the printer stamp prematurely contacts the
label ribbon, reduce the PDT setting value.
4.4.15 Printer dwell time
(PDWT)
When using a printer (optional):
– Set the dwell time for the printer (printing time).
In the extended menu:
£ Call up the PDWT function.
£ Set the desired value.
– Settings are possible in 1 ms steps:
Minimum: 0 ms
Maximum: 1000 ms
£ Confirm the setting using the ENTER key and exit
the function.
The printer stamp is blocking the label feed.
£ When setting the printing time, ensure that
the printing process has finished before the
next label feed begins
– The greater the labelling speed, the less the
possible printing time.
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OPERATION
4.4 SETTINGS IN THE EXTENDED MENU
4.4.16 Tandem operation
(TMOD)
4.4.22 Delete a product data bank
(LOAD)
Activate and deactivate tandem operation
– Refer to chapter Tandem operation in the service
guide.
Selecting and loading a product data bank.
– Refer to chapter Product databanks, Page 61.
4.4.17 Applicator type
(APPL)
4.4.23 Create/save product data bank
When using an applicator (optional):
Set the applicator type used or switch off the applicator.
(SAVE)
Create a new product data bank.
– Refer to chapter Applicator (optional), Page 82.
– Refer to chapter Product databanks, Page 61.
4.4.18 EP cylinder dwell time (APT1)
4.4.24 Delete a product data bank
When using an EP applicator (optional):
Set the dwell time for the cylinders.
(DEL)
– Refer to chapter Applicator (optional), Page 82.
– Refer to chapter Product databanks, Page 61.
4.4.19 Blowing time
(APT2)
When using a blowing applicator (optional):
Set the dwell time for blowing the label on the product.
– Refer to chapter Applicator (optional), Page 82.
4.4.20 Delay time
(APT3)
When using an EP applicator (optional):
Delay of the signal air blow
– Refer to chapter Applicator (optional), Page 82.
4.4.21 Fine tuning of the dwell time
(APT4)
When using an applicator (optional):
Fine adjust the dwell time of the applicator in combination with the automatic dispensing speed adjustment.
By doing this, the accuracy of the label position on the
product can be optimised.
– Refer to chapter Applicator (optional), Page 82.
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OPERATION
4.5 AUTOMATIC DISPENSING SPEED (APSF)
4.5
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AUTOMATIC DISPENSING SPEED (APSF)
4.5.1 Principle of operation
A
[86] A RPM transmitter (speed sensor) on the conveyor line
Conveyor belt and label dispenser are operating in perfect synchronisation. As a prerequisite for this, the RPM
transmitter must be correctly adjusted. Depending on
the operating conditions, the relationship between the
dispensing speed and the conveyor belt speed must be
finely adjusted (EGRA function).
The automatic dispensing speed (APSF) makes it possible to automatically adapt the dispensing speed to the
speed of the conveyor belt. The speed of the conveyor
belt is picked up by a speed sensor [86A] and transmitted to the control system of the labeller. The control
system calculates the permanent position and speed of
the products. The resulting values are used for controlling label feed, unwinding, and rewinding and are constantly monitored and regulated. Fluctuations in the
conveyor belt speed are automatically compensated
for. If the conveyor belt stops, the label dispenser also
stops.
Only servicing technicians are permitted to configure the label dispenser for APSF mode. For
further information, refer to the service guide.
The conveyor belt can stop even while a label is being
dispensed. The label feed is then stopped as well. Only
when the belt starts running again, does the label feed
move the label to the next gap on the label ribbon.
80
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OPERATION
4.5 AUTOMATIC DISPENSING SPEED (APSF)
4.5.2 Electronic transmission ratio
of the RPM transmitter (EGRA)
– Required compensation factor, in the event that an
RPM transmitter with a resolution other than
0.157 mm/pulse is used.
Setting the compensation factor
£ Calculate the setting value for EGRA:
A = resolution of the RPM transmitter used in mm/pulse
– Possible settings:100 ... 1,000, corresponds to resolutions from 0.10 ... 1 mm/pulse
£ In the extended menu, call the EGRA function.
£ Input the calculated setting value and exit the EGRA
function.
The setting of the electronic transmission ratio
affects the dispensing speed:
– The smaller the EGRA compensation factor,
the greater the dispensing speed.
– When the EGRA has a low setting value and
a high conveyor belt speed, the allowable
dispensing speed can be exceeded.
– If the dispensing speed is too great, the
warning message W__4 appears.
Test the setting
£ Remove the pressure roller unit (optional) at the dispensing edge.
£ Start the system.
– The labelling speed is too low if the product pulls the
label away from the backing material.
– The labelling speed is too high if the label on the
product has folds in it.
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OPERATION
4.6 APPLICATOR (OPTIONAL)
4.6
APPLICATOR (OPTIONAL)
4.6.1 Principle of operation
If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator. In
applicator mode, the applicator takes the label from the
dispensing edge and carries it to the product.
The labeller can be equipped with various applicators,
depending on the need. The following are possible:
– Air Stream Applicator (pneumatic applicator):
Using suction, the applicator takes the label from the
dispensing edge, transports it until it is directly in
front of the product and then blows the label onto it.
– Electro-pneumatic Applicator (EP applicator):The
applicator uses suction to take the label from the
dispensing edge. Then a pneumatic cylinder extends and presses the label onto the product.
– Electro-pneumatic Applicator (EP applicator):The
applicator uses suction to take the label from the
dispensing edge. Then a pneumatic cylinder with
the label traverses into the application position and
waits there for the product. When the product reaches the pneumatic cylinder, it presses the label onto
the product.
By means of the APPL function in the extended menu,
the controller is adjusted to the applicator currently in
use
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OPERATION
4.6 APPLICATOR (OPTIONAL)
4.6.2 Functions in the extended
menu
Please observe the following:
CAUTION!
Erroneous settings can lead to production
setbacks, damage to the machine and system, and can even cause work-related accidents!
– Only specially trained and instructed personnel may alter the settings in the extended menu.
Calling up the extended menu.
£
–
£
–
Simultaneously press the NEXT and PRIOR keys.
CODE appears on the LED display.
Enter the password [87].
The following appears on the LED display for approx. 1 second: * * * *
– The extended menu is active.
Applicator type
[87] Key sequence (password) for the extended menu
(APPL)
– Set the applicator type used or switch off the applicator.
In the extended menu:
£ Call up the APPL function.
£ Set the desired type.
– Possible settings:
ASA Air Stream Applicator
EP: Electro-pneumatic applicator
REVP: Reverse electro-pneumatic applicator
DIR: Dispense directly from the dispenser head
without using the applicator
£ Confirm the setting using the ENTER key and exit
the function.
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OPERATION
4.6 APPLICATOR (OPTIONAL)
EP cylinder dwell time
(APT1)
– Dwell time for the EP cylinder
In the extended menu:
£ Call up the APT1 function.
£ Set the desired value.
– Settings are possible in 1 ms steps:
1 ... 7500 ms
£ Confirm the setting using the ENTER key and exit
the function.
Blowing time
(APT2)
When using a blowing applicator:
– Dwell time for blowing the label on the product
In the extended menu:
£ Call up the APT2 function.
£ Set the desired value.
– Settings are possible in 1 ms steps:
1 ... 7500 ms
£ Confirm the setting using the ENTER key and exit
the function.
Delay time
(APT3)
When using an EP applicator:
– Delay of the signal air blow.
The signal controls the air blow which blows the label onto the underside of the applicator. The value
for APT3 is the delay between the start of label dispensing and activation of the air blow.
In the extended menu:
£ Call up the APT3 function.
£ Set the desired value.
– Settings are possible in 1 ms steps:
1 ... 5000 ms
£ Confirm the setting using the ENTER key and exit
the function.
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OPERATION
4.6 APPLICATOR (OPTIONAL)
Fine tuning of the dwell time
(APT4)
When using an applicator in combination with the automatic speed adjustment (APSF):
– Optimise the accuracy of the label position on the
product by fine tuning the dwell time for the applicator.
Standard values:
– Blowing applicators: approx. 25 ms
– EP applicators: 60 ms ... 100 ms, depending on the
length of the stroke
Prerequisite:
– External RPM transmitter is calibrated (EGRA function)
Determining and setting the exact value [88]:
£ Call up the APT4 function in the extended menu.
£
£
–
£
Set the setting value for APT4 to 1.
Allow the conveyor belt (with products) to run slowly.
Speed vN = 10 m/min
Document the position of the label on the product:
Value: POSN in mm
[88] Label position in relation to the conveyor belt speed
vN - Low conveyor belt speed
POSN - Label position at lower conveyor belt speed
vH - High conveyor belt speed
POSN - Label position at higher conveyor belt speed
£ Increase speed of the conveyor belt to approx.
25 m/min (value vH).
£ Document the position of the label on the product:
Value: POSH in mm
£ Calculating the setting value for APT4:
£ Input the calculated setting value.
£ Confirm the value using the ENTER key and exit the
function.
Test the setting:
£ Test the labelling accuracy at different conveyor belt
speeds.
£ If necessary, correct the setting value for APT4:
– The greater the value for APT4, the farther forward
the label is applied.
– The smaller the value for APT4, the farther to the
rear the label is applied.
85
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AFTER OPERATION
5.1 CARE AND CLEANING
5
A FT ER O P ER A TIO N
5.1
CARE AND CLEANING
5.1.1 Cleaning agents
5.1.2 Regular maintenance
Cleaning agents for rubber rollers:
– Roller cleaner, ordering code 98925
If other cleaning agents are used, there is
some risk of dissolving the rubber.
The labeller is designed to be maintenance-free. Nevertheless, to ensure long-lasting and reliable operating results, regular maintenance is required.
Depending on operating conditions, at least weekly:
£ Carry out the cleaning and maintenance work described in the following.
Cleaning agents for adhesive residues:
– Label loosening spray
Other cleaning agents:
– Isopropyl alcohol
CAUTION!
Isopropyl alcohol is flammable!
£ Keep cleaning agents and used rags
away from open flames and other sources of ignition.
Isopropyl alcohol vapours can cause headaches, nausea, dizziness, or eye irritation.
£ Only use it in well ventilated areas.
£ Do not ingest it.
Prolonged contact with the skin depletes the
skin’s natural oils, which can lead to irritation.
£ Avoid contact with the skin if possible. If
you have sensitive skin, wear gloves.
CAUTION!
Unsuitable cleaning agents can cause considerable damage to the machine!
£ Do not use cleaning agents that could
damage or destroy the painted surfaces,
lettering, the display, identification
plates, electrical components, etc. Observe the information provided by the
cleaning agent manufacturer.
£ Do not use abrasive or plastic-dissolving
cleaning agents.
£ Do not use any acidic or alkaline solutions.
86
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AFTER OPERATION
5.1 CARE AND CLEANING
Remove paper waste
£ Wipe off all paper waste (dust) from all rollers and
edges.
£ Clean the optics of the photoelectric sensors with a
soft brush or a soft tissue.
Braking brush
£ Loosen the stud bolts [89A] and remove the braking
brushes.
£ Remove adhesive residues
£ Turn the braking brushes and reinstall them so that
the side opposite the deformed bristles bears the
load.
A
[89] Braking brush
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AFTER OPERATION
5.1 CARE AND CLEANING
Capacitive sensor at the dispenser head
Only if the labeller is equipped with a capacitive sensor
[90A] instead of the proper photoelectric sensor:
£ Remove the knurled thumb screw [90B].
£ Remove 2 screws on the underside [91A].
£ Remove the upper part of the housing [92A].
£ Clean the sensor surfaces [92 arrows] with soft,
lint-free rags.
A
£ Reassemble the sensor.
£ Test the sensor adjustment.
B
[90] A Capacitive sensor
B Knurled thumb screw
A
[91] A Fastening screws for the housing on the underside
A
[92] A Upper part of the housing with sensor surfaces (arrows)
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OPERATIONAL MALFUNCTIONS
6.1 WARNING MESSAGES
6
O P E RA TI ON A L M AL FU NC TI ON S
6.1
WARNING MESSAGES
6.1.1 Please observe:
6.1.2 If a problem occurs
CAUTION!
Improper handling of the machine, especially changes to the settings, can lead to serious damage to the machine and system and
can cause work-related accidents!
– Only servicing technicians or the customer service personnel are authorized to
make changes to the settings in the configuration menu.
£ Ensure that the other settings are carried
out exclusively by specifically trained
and knowledgeable personnel.
Observe the expert symbols.
£ Observe the additional information in this
operating instruction or in the service
guide.
The control system detects a problematic or unacceptable situation:
– A warning message is displayed on the operator
panel.
– As a rule, the labelling operation is continued, if the
operator does not stop the machine.
If the cause of the warning message is eliminated:
– The warning code is no longer displayed.
6.1.3 Warning messages
Message
Description
Possible causes and remedies
W__0
Product was not labelled.
£ Remove the unlabelled product.
Several labels are missing from the label ribbon:
£ Replace the label roll if the error occurs frequently.
The distance between the products on the conveyor
belt is insufficient:
£ Increase the product distance.
£ For circumferential labelling: Increase the rotational speed.
The product triggers several start signals, caused by
reflections, for example:
£ Adjust the product length (PRDL).
When using a printer, the printing time is too long:
£ If possible, decrease the printer dwell time
(PDWT).
£ Start printing process before label stop (PDT).
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OPERATIONAL MALFUNCTIONS
6.1 WARNING MESSAGES
Message
Description
Possible causes and remedies
W__2
Memory errors
Factory settings are activated, see
Appendix.
CPU battery is discharged after a long shut-down period of
the machine:
£ Leave the machine switched on for some time to recharge the battery
If the accumulatorerror occurs frequently:
£ Have the CPU battery replaced by the customer
service.
Settings no longer available after software update.
Settings must be input again by a servicing technician; refer to service guide.
W__3
Too many labels between label stop
sensor and dispensing edge.
W__4
Dispensing speed is too high.
This negatively affects position
accuracy.
Label stop sensor must be adjusted by servicing
technician; refer to service guide.
£ Reduce dispensing speed (VELO), if the warningmessage is frequently displayed for long periods.
For automatic dispensing speed (APSF):
A check of the EGRA function is required
£ Insert new labelling material.
W__5
The roll diameter control (optional)
reports the end of the label roll.
W__6
Data transmission error at the V24
interface
The cables, plug connections, and interface parameters must be checked by servicing technicians; refer to service guide
W__7
Label position on the product too
close to the product’s leading edge
and high dispensing speed
£ Increase the setting value for POS, decrease dispensing
speed (VELO).
If this is not possible or the warning message
reappears:
The settings in the configuration menu must be
checked by servicing technicians; refer to service
guide.
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OPERATIONAL MALFUNCTIONS
6.2 ERROR MESSAGES
6.2
ERROR MESSAGES
6.2.1 If a malfunction occurs
If the control system detects a serious error:
– The labelling operation is stopped.
– An error code is displayed on the operator panel.
If the cause of the error has been eliminated:
£ Acknowledge the error message by pressing the
ENTER key.
6.2.2 Error codes
Message
Description
Possible causes and remedies
E__1
The loop space is not filled.
Label roll empty:
£ Replace label roll.
Pressure roller not closed:
£ Swing up the pressure roller on the drive roller unit’s unwind unit and return it to its position pressing against the
roller. The pressure roller clicks neatly into its operating
position.
Unwind unit drive defective:
– Repair by servicing technician is required; refer to
service guide
The photoelectric sensor in the loop
space does not actuate.
Reflective surface is dirty:
£ Clean the reflective surface.
Use of very bright labels or
Sensor potentiometer out of adjustment or
Sensor defective:
– Adjustment/replacement by servicing technician is
required; refer to service guide
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OPERATIONAL MALFUNCTIONS
6.2 ERROR MESSAGES
Message
Description
Possible causes and remedies
E__2
Label stop sensor does not detect
the labels.
Ribbon of labels does not run through the slot in the photoelectric sensor:
£ Check the ribbon guide at the label stop sensor.
Label roll empty or more than 3 labels missing:
£ Replace label roll as required.
Pressure roller not closed:
£ Swing back the lower pressure roller and return it to its
position pressing against the feed roller unit. The pressure roller clicks neatly into its operating position.
Insufficient labelling speed:
– The product pulls the label off of the base material.
£ Synchronise the labelling speed and product speed
(VELO function).
Other options:
£ Manually adjust the sensitivity of the label stop
sensor (CONT).
£ Check the label stop position (STOD).
£ Check the label distance setting (LPIT).
£ Check to see whether the feed motor behind the
dispenser head is running.
E__3
The photoelectric sensor in the loop
space does not detect the loop formation and the label stop sensor
does not detect the labels.
Refer to E__1 and E__2; First check the loop formation.
E__4
Rewind unit problems
Label roll empty:
£ Replace label roll.
Label ribbon torn:
£ Rethread the label ribbon at the rewind unit.
Rewinding motor runs too slowly or is defective:
– Setting or adjustment by servicingtechnician is required; refer to the service guide
E__5
Refer to E__1 and E__4.
Photoelectric sensor in the loop
space does not detect the loop formation and problem with the rewinding unit.
E__6
Label stop sensor does not detect
the labels and problem with the rewind unit.
Label ribbon torn:
£ Rethread the label ribbon at the rewind unit.
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OPERATIONAL MALFUNCTIONS
6.2 ERROR MESSAGES
Message
Description
Possible causes and remedies
E__7
Photoelectric sensor in the loop
space does not detect the loop formation; label stop sensor does not
detect the labels and problem with
the rewind unit.
Refer to E__1, E__2, and E__4.
E_10
Error at applicator
When using an EP applicator:
The applicator must be checked by servicing technicians.
E_11
Many products are not labelled. The
number of unlabelled products is
greater than the amount set in the
MLAB function.
The distance between the products on the conveyor
belt is insufficient:
£ Increase the product distance.
£ For circumferential labelling: Increase the rotational
speed.
The product triggers several start signals, caused by
reflections, for example:
£ Adjust the product length (PRDL function).
When using a printer, the printing time is too long:
£ If possible, decrease the printer dwell time (PDWT
function).
£ Start printing process before label stop (PDT function).
Several labels are missing from the label ribbon:
£ Replace label roll
or
£ Increase value for MLAB, if possible.
Erroneous settings in the extended menu:
£ Check the POS2 and POS3 settings.
E_12
Invalid setting value Factory settings
are activated, see Appendix.
E_13
Label roll is completely consumed.
Labels are no longer detected at the
label stop sensor.
A serious memory error has occurred:
– The control system needs to be reconfigured by a
servicing technician or the customer service; refer
to the service guide.
£ Replace label roll.
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OPERATIONAL MALFUNCTIONS
6.2 ERROR MESSAGES
Message
Description
E_14
Too many products between product
sensor and dispensing edge.
Possible causes and remedies
Product sensor located too far from dispensing edge:
– A maximum of 7 products can be located between
the product sensor and the dispensing edge.
£ Change the position of the product sensor.
£ Subsequently correct the POS setting.
The product triggers several start signals, caused by
reflections, for example:
£ Adjust the product length (PRDL function).
E_15
Short circuit
or
Overload of outputs from CN10
ER-U
Software error
ER-I
Software error
ER-D
Software error
ER-T
Software error
ER-A
Software error
A check of the connections and output signals by
servicing technicians is required; refer to the service
guide.
£ Press the ENTER key.
£ Make note of all the information that is displayed on the
control panel.
£ Make note of what happened before the error occurred.
£ Inform Avery Dennison’s customer service.
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APPENDIX
7.1 FACTORY SETTINGS
7
7.1
A P PE ND IX
FACTORY SETTINGS
In the case of a memory error:
– The message W__2 or E_12 appears on the
operator panel.
– All databanks are deleted.
– The settings of the machine are reset to factory settings [93].
Function
Value
Explanation
VELO
0500
Labelling speed: 50.0 m/min
STOD
0000
Distance between dispensing edge and label's leading edge: 0.0 mm
POS
0500
Distance between leading edge of product and label: 50.0 mm
POS2
0000
Multi-labeling: Distance between the leading edges of the first and second label: 0,0 mm
POS3
0000
Multi-labeling: Distance between the leading edges of the second and third
label: 0,0 mm
VERT
0100
dispensing speed = conveyor belt speed
CONT
0035
Sensitivity of the label stop sensor
LPIT
1000
Label distance = 100.0 mm
E-SS
0016
Distance between label stop sensor and dispensing edge: 16 mm
PRDL
AUTO
Product length = LPIT
P_S_
LEDG
Product sensor: Triggered by leading edge
S_S_
LEDG
Label stop sensor: Triggered by leading edge
MLAB
0000
Machine stops as soon as one product is not labelled
PDT
0000
Label stop = Printer start
PDWT
0000
Printer dwell time: 0.0 s
EGRA
0600
Compensation factor for RPM transmitter for automatic speed adjustment
TMOD
OFF
Tandem operation deactivated
APPL
DIR
Applicator mode deactivated
APT1
0001
EP cylinder dwell time: 1ms
APT2
0001
Blowing time: 1ms
APT3
0000
Delay time: 0ms
APT4
0001
Fine tuning of dwell time: 1ms
MDIR
Turning direction of all motors for right-hand version
OMOD
ON
Machine goes into online mode (operation-ready) after switch-on
TAND
0000
Distance between product-sensors during tandem operation: 0.0 mm
SLEW
0055
Dispense speed during missing label compensation: 55 m/min
COMP
ON
Automatic label compensation deactivated
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APPENDIX
7.1 FACTORY SETTINGS
Function
Value
Explanation
LABC
0000
Label counter is reset to „0“
APSF
OFF
Automatic dispensing speed switched off
BAUD
NONE/9600
PARI
NONE
SBIT
0001
NUMB
0001
PRNT
STAM
(Settings for data transmission to the serial interface)
Heat transfer printer selected
[93] Factory settings
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APPENDIX
7.2 PRODUCT DATABANKS
7.2
PRODUCT DATABANKS
Client/Order
Function
Data base
PD01
PD02
PD03
POS
POS2
POS3
VELO
STOD
CONT
E–SS
LPIT
PRDL
P_S_
S_S_
MLAB
PDT
PDWT
EGRA
VERT
APPL
APT1
APT2
APT3
APT4
Date:
Signature:
97
PD04
PD05
PD06
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ALS
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APPENDIX
7.2 PRODUCT DATABANKS
Client/Order
Function
Data base
PD07
PD08
PD09
POS
POS2
POS3
VELO
STOD
CONT
E–SS
LPIT
PRDL
P_S_
S_S_
MLAB
PDT
PDWT
EGRA
VERT
APPL
APT1
APT2
APT3
APT4
Date:
Signature:
98
PD10
PD11
7
APPENDIX
7.3 EC DECLARATION OF CONFORMITY
7.3
ALS
350
450
EC DECLARATION OF CONFORMITY
We, the:
Avery Dennison Deutschland GmbH
Ohmstraße 3
D–85386 Eching
hereby declare that we have designed and constructed the following designated machine in such a way that it complies with the basic safety and health requirements of the EC Directive.
Machine designation:
ALS 350/ALS 450
Machine type:
Labeller
Serial number:
Comprised of a running number (5 digits) +
date code (YY/MM) +
ending (machine designation): –ALS350 / –ALS 450
(Example: 040060309–ALS350)
Relevant EU directives:
Machinery Directive 98/37/EC,
EMC Directive 89/336/EEC
Low Voltage Directive 73/23/EEC
Applicable Harmonized
Standards, in particular:
EN ISO 12100: 2003 (Safety of Machinery)
EN 294: 1992 (Safety of Machinery)
EN 61000–6–3: 2001 (Emission standard for residential, commercial
and light industrial environments)
EN 61000–6–2: 2001 (Immunity for industrial environments)
EN 61000–3–2: 2000 (Limits for harmonic current emissions)
EN 61000–3–3: 1995 + A1:2001 (Limitation of voltage fluctuations and
flicker)
Eching, 19 July, 2004
Markus Roderer (General Manager)
99
Avery Dennison Deutschland GmbH
Postfach 1163
85385 Eching
Germany
Telephone: +49-8165-925-0
http://www.machines.averydennison.com