Avery Dennison holds all rights to this manual and its appendices. Reproduction, reprinting or any other types of duplication, even of portions of this manual, may only be carried out with express written consent.

Third persons, in particular competitors, should not be given access to the information in this manual.

Printed in Germany

Manufacturer

Avery Dennison Deutschland GmbH

Ohmstrasse 3

85386 Eching, Germany

Phone: +49-8165-925-0

Fax: +49-8165-3143 http://www.machines.averydennison.com

Technical status

Technical status: 04/2007

Software version: 1.02

ALS

20x

256

Avery Dennison reserves the right:

– To make modifications to construction parts, components and software, as well as to employ comparable components in place of the parts specified, in keeping with technical advances.

– To modify information in this document.

No commitment will be made to expand these modifications to include any units delivered earlier.

1.1 G

ONTENTS

ENERAL NOTES

1.1.2

Illustrations and descriptions

Signs and symbols

Various information types are indicated in different ways within the document in order to simplify readability and comprehension.

Sentences starting with an arrow are instructions and guidelines.

£ Perform the instructions one after another in the specified order.

The following information begins with a dash:

– Lists

– Mode descriptions

– Descriptions of prior steps

– Prerequisites for following actions

Figures

Texts are accompanied by figures where necessary.

Figures are indicated using figure numbers in [square brackets]. A capital letter after a figure number, for example [12A], refers to a specific section of the figure.

Generally, the label dispenser shown is an ALS 104 right-handed version. The left-handed version is only shown where it is necessary to differentiate between the two.

Dangers and risk notes

Important directions that you must absolutely observe are particularly emphasized:

WARNING!

A warning refers to risks that can lead to serious injury or death! The warning contains safety measures to protect the relevant persons.

£ Always follow the instructions.

CAUTION!

A caution indicates risks that can lead to property damage or injuries to persons

(minor injuries). The caution note contains instructions for preventing damages.

£ Always follow the instructions.

Button symbols

– The buttons of the control panel are depicted as symbols.

– The symbols are depicted with a ‘+’ (PLUS SIGN) between them if more than one button is to be

Parameters

Parameters are displayed in grey in the text with the following structure,

MENU NAME > Function name

Supplementary information

The expert symbol indicates actions that are only to be performed by qualified and specially trained personnel.

The information symbol indicates notes and recommendations, as well as additional information.

Equipment:

– Equipment, for example lubricants or cleaning agents

ALS

20x

256

1.2 S

ONTENTS

AFETY INSTRUCTIONS

1.2

SAFETY INSTRUCTIONS

1.2.1

Information and qualifications

Follow the instructions

WARNING!

Safe and efficient operation of the label dispenser can only be guaranteed if you observe all necessary information.

Product liability and warranty claims can only be asserted if the unit was operated in accordance with the directions in the manual.

£ Before operating the unit, read the operating instructions and all other notes carefully.

£ Observe the additional safety and warning notes on the label dispenser.

£ Only permit competent people to operate and configure the label dispenser.

Ensure the required qualifications are met

£ Ensure that only trained and authorized personnel operate, configure and service the unit.

£ Only allow qualified and well-trained expert personnel or service technicians to perform configurations.

£ The responsibilities with regard to operation, configuration and maintenance should be clearly defined and consistently maintained.

£ In addition, personnel should also be instructed on a regular basis in matters of occupational safety and environmental protection.

Keep the product information at hand

With respect to this manual:

£ It should be kept at the location where the unit is installed and be available to the operator.

£ It should always be legible.

£ If the unit is sold, the manual should be made available to the new owner.

£ The safety and warning notes affixed to the unit itself must be kept clean and legible.

Missing or damaged signs must be replaced.

Qualification for operation

The instruction of personnel using the unit must ensure that:

– The operating personnel can use the unit on their own and safely.

– The operating personnel can remedy small operational disruptions on their own.

£ At least two people must be instructed in the unit’s usage.

£ Enough label material must be provided for testing and instructional purposes.

Qualifications for configuring

The configuration of the controls requires qualified expertise:

– Personnel configuring the unit must be acquainted with the functionality of the label dispenser.

– Personnel configuring the unit must be acquainted with the modes of operation within the facility in which the label dispenser is integrated.

– The personnel configuring the unit must be able to use the additional menus properly and appropriately for specific project requirements.

ALS

20x

256

1.2 S

ONTENTS

AFETY INSTRUCTIONS

1.2.2

Operational safety of the unit

Proper usage

The ALS 20x Label Dispenser is a fully automatic unit for attaching self-adhesive labels to products or packaging. The company operating the unit must install it with suitable equipment to protect operating personnel from danger; for example, the danger of the hands or fingers being crushed by reaching in between the product and the dispensing edge.

WARNING!

Improper usage of the unit can cause accidents, property damage and production downtime!

£ Only use the unit in accordance with the instructions specified in this manual.

£ Do not operate the unit without the required safeguards.

£ Only configure the unit in accordance with this manual and with the required care.

£ Only use original accessories.

£ Do not make any modifications or alterations to the unit.

£ Repairs to the device may only be performed by authorised specialists who are aware of the risks involved.

Protection against injuries by electrical current

WARNING!

The machine operates using mains voltage!

Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns.

£ Only operate the unit once the housing has been reassembled properly.

£ Only connect the unit to a properly fitted power socket that is grounded.

£ Before cleaning, switch off the unit and remove the power cable from the socket.

£ Only link the unit to devices that fulfil the

SELV (safety extra-low voltage) circuit requirements specified in EN 60950.

WARNING

The unit is not protected against splashing water in its standard model.

£ Keep the unit dry.

£ If liquids have penetrated the unit, switch it off and disconnect or unplug the power cable immediately. Inform a service technician.

WARNING

The device is only completely disconnected from the mains if the power cable is unplugged.

£ Make sure the power supply socket is accessible.

£ In case of emergency, switch off the device and disconnect the power cable.

CAUTION

A too high or low supply voltage can damage the unit.

£ Only operate the device using the system voltage indicated on the nameplate.

£ Ensure that the mains voltage set on the unit is the same voltage as that provided by the electricity supplier.

ALS

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256

ONTENTS

1.2 S

AFETY INSTRUCTIONS

Protection against injuries by mechanical action

WARNING!

Risk of injury due to moving and rapidly rotating parts!

– Long hair, loose jewellery, long sleeves, and so on are not permissible when using the unit.

£ Sufficient protective clothing must be worn.

£ Keep moving parts free from obstructions even when the unit is not switched on, if there is a chance the machine might be turned on.

£ Switch off the machine before making any mechanical settings.

£ Do not wear ties, loose clothing, jewellery, wrist watches or similar items on your person when near the operating unit.

WARNING!

There is a risk that you may get your fingers or hands crushed on the dispensing edge by products on the conveyor belt!

£ Never reach between the product and the dispensing edge while the unit is in operation or ready for operation.

£ Never reach behind the safety guard or remove it while the unit is in operation.

Protection against injuries by chemicals

CAUTION!

Operating materials such as cleaning agents or the solvents in glues can be damaging to health.

£ Always follow the instructions, use and safety regulations specified by the manufacturer!

ALS

20x

256

1.2 S

ONTENTS

AFETY INSTRUCTIONS

1.2.3

Before beginning production

Due diligence of the operating company and the service technician

£ Ensure that the following prerequisites are fulfilled in accordance with the service instructions:

– The machine is installed properly and configured in accordance with the guidelines.

– All required safety mechanisms have been installed.

– The unit has performed at least one successful test run.

– The unit is connected to the power supply.

£ The users have the required personal protective equipment, for example, a hairnet. Ensure that the protective equipment is utilised correctly.

Due diligence of the user

£ Check that the safety installations are working properly.

£ Inspect the machinery for any visible damage.

Report any ascertained defects immediately.

£ Use the required personal protective equipment correctly, for example, wear a hairnet.

£ Remove any unnecessary materials and objects from the operating area of the unit.

£ Ensure that only authorised persons are within the operating range of the machine.

£ Ensure that starting up the machine will not injure anyone.

ALS

20x

256

ONTENTS

1.2 S

AFETY INSTRUCTIONS

1.2.4

Safety notes on the unit

CAUTION!

Warning notes on the unit represent important information for the personnel using it.

£ Do not remove warning notes.

£ Replace any missing or illegible warnings.

The ‘Pinch Point’ warning [1] note warns you of the

danger posed by the machine’s rotating parts; they can trap items and draw them in.

WARNING

Pinch point.

Keep hands clear of rollers.

A5346

[1] Left: ‘Pinch Point’ warning. Right: Position of the warning note on the ALS 20x. Item number of the label: A5346.

The blue label ‘Read manual’ [2] demands that users

read the unit instructions.

Handbuch lesen!

Read the manual!

Lisez le manuel!

Lea el manual!

Legga il manuale!

[2] Left: ‘Read manual’ notice. Right: Position of the notice on the ALS 20x. Item number of the label: A5331.

ALS

20x

256

ONTENTS

2.1 O

VERVIEW

R O D U C T D E S C R I P T I O N

2.1

OVERVIEW

2.1.1

Components

B

C

A

D

O

N

M

L

K

[3] ALS 204 Label Dispenser (right-handed version)

J

I

G

H

E

F

ALS

20x

256

2.1 O

ONTENTS

VERVIEW

A Control panel

– For sending commands to the device and for displaying operating states and error messages.

– An optional external control panel can also be connected to the device.

B Dancer arm

– Keeps the label material stretched tight evenly.

– Arrests the rotation of the material roll if tension diminishes.

C Dispenser

– Dispenser mandrel grasps the label roll.

D Core diameter adapter

– For adjusting the diameter of the dispenser mandrel to match the core diameter of the label roll.

E Adjusting knob

– Turning this in a clockwise direction secures the label roll on the dispenser.

F Deflection rollers

G Dispensing edge bracket

H Label sensor

– Stops the label feed after a label has been dispensed.

I Pressure roller

– Prints the label once it is stuck to the product.

J Dispensing edge

– Standard: (non-adjustable) L-shaped dispensing edge

– The following options are available: V-shaped dispensing edge, adjustable L-shaped dispensing edge, spring-loaded L-shaped dispensing edge, pneumatic L-shaped dispensing edge

K Drive roller

– Drives the label material forwards.

L Pressure mechanism

– Presses the pressure roller against the drive roller.

– Prevents the backing paper from slipping through.

– Releases automatically once the backing paper has been drawn around the drive roller.

M Dancer arm

– Controls the rewind speed.

N Rewinder

– Rolls up the used backing paper.

O Release button

– Pressing this button reduces the diameter of the rewinder core.

– Allows the easy removal of the rewound backing paper.

ALS

20x

256

ONTENTS

2.1 O

VERVIEW

2.1.2

Control panel

Operating LED

Lights up green when the device is switched on.

Error LED

Lights up red when an error occurs.

LCD display

– Displays functions, configured values, operating states and error messages.

– What is displayed at any one time depends on the operating status of the device; these screens are

explained in the section “Operating modes” on page 21.

Buttons

The functions of the buttons depend on the operating status of the device; these functions are explained in

the section “Operating modes” on page 21.

A

B

C

D

STATUS

Online

Labels

–

292

+ – +

[4] The ALS 20x control panel (in dispensing mode)

A Operating LED

B Error LED

C LCD display

D Buttons

ALS

20x

256

ONTENTS

2.1 O

VERVIEW

2.1.3

Connection arrangement

Connections on the back of the device

H

B

C

D

E

F

G

ALS

20x

256

A

[5] Connections on the back of the device (ALS 20x):

A Power supply connection

B Network connection (Ethernet 10/100)

C Serial interface (RS232)

D Connection for external control panel (RS485)

For information on connecting the unit, see sec-

tion “Power supply connection” on page 29.

E Plug-in card slot (CompactFlash cards)

F USB device interface

G PLC signal interface

H Optional: Applicator interface

ONTENTS

2.1 O

VERVIEW

Sensor connections

C B

A

E

PLC-IN

G

D

PLC-OUT

F

START

ROTARY

ENCODER

H

LABEL

CAP CAP for 256

[7] Arrangement of the sensor connections (schematic) on the LH

(left figure) and RH (right figure) devices:

A Product sensor

B Signal outputs (optional)

C Signal inputs (optional)

D Rotary encoder (for automatic speed adaption)

E Roll diameter sensor

F Label sensor

G (ALS 20x) Alternative label sensor

H (ALS 256) Alternative label sensor

For information on connecting the sensors, see

section “Connecting sensors” on page 31.

[6] Sensor connections on the ALS 20x (RH)

B C

A

F

START

D

PLC-OUT PLC-IN

E

LABEL

H

ROTARY

ENCODER

G

CAP for 256

CAP

ALS

20x

256

2.1 O

ONTENTS

VERVIEW

2.1.4

Mode of operation

In labelling mode, the strip is first pulled from the label

roll around the dancer arm [8A], which consistently

maintains even tension in the label strip. The feed roller

[8D] behind the dispensing edge [8C] draws the strip

across the dispensing plate. The label is unfixed from the backing paper on the dispensing plate and is

pressed onto the product by the pressure roller [8B].

The feed roller drives the label strip forwards the length of one label and stops until the next product arrives at the dispensing plate. The strip feed is started by the product sensor mounted on the conveyor belt. The stop control provided by the label sensor on the dispensing edge ensures the feed is halted as soon as a gap is detected between two labels.

The spent backing paper runs from the dispensing

edge around the drive roller [8D] to the rewinder [8E].

The dancer arm regulates the rewinding speed.

The entire operation of the label dispenser is controlled and monitored electronically. If errors occur, the device controls output an appropriate notification for the operator. If necessary, the labelling operating mode is halted automatically. An electronic signal is output at the same time. The signal can be fed to an external controller and evaluated.

A

E

D

B

C

[8] The ALS 20x Label Dispenser is ready for operation in its idle mode.

A Dancer arm

B Pressure roller

C Dispensing edge

D Drive roller

E Rewinder

ALS

20x

256

2.1 O

ONTENTS

VERVIEW

2.1.5

Technical specifications

Characteristics

Dispensing speed

ALS 204

ALS 206

ALS 256

Labelling halt precision

2) at the peeling edge: max. 40 m/min max. 30 m/min max. 50 m/min

±1 mm

Speed control: Fixed setting or automatic speed adaption via the rotary encoder

1) The maximum usable dispensing speed depends on the label geometry.

For details see separate performance matrix.

2) At a dispensing speed range of 5 m/min to the max. speed

Labels

Label material:

Internal rewinding

Material width (including backing paper)

ALS 204

ALS 206

ALS 256

Label length:

Label roll:

Winding direction

Dispenser (outer) Ø:

Rewinder (outer) Ø:

Core (inner) Ø:

Converted self-adhesive label material with liner yes up to 110 mm up to 160 mm up to 160 mm

5 to 600 mm inner or outer up to 300 mm up to 200 mm

38.1 / 76.2 / 101.6 mm

(1.5 / 3 / 4 ")

3) Depending on the dispensing edge width.

Label sensor

Distance to peel edge

L-shape dispensing edge:

V-shape dispensing edge:

Transmission sensor:

19 mm

77 mm

Wenglor OPT242-P800 optical, NPN

Power supply

System voltage:

ALS 20X

ALS 256

110 V (AC) at 60 Hz power frequency (permissible tolerance ±10%)

230 V (AC) at 50 Hz power frequency (permissible tolerance ±10%)

100-240 V (AC) at

50-60 Hz power frequency (permissible tolerance

±10%)

Power consumption:

ALS 20X

ALS 256

Fuses:

ALS 20X

ALS 256 max. 460 VA max. 560 VA

F1, F2: T5AH 250 V

Fuses integrated in the power supply

4) For more information on fuses, see section “Replacing fuses” on page 47.

5) Not accessible for user or service technician.

ALS

20x

256

2.1 O

ONTENTS

VERVIEW

Electronics

Processor:

RAM:

ROM:

Control panel:

32 Bit CPU MIPS Core

16 MB

4 MB graphical display with

128 x 32 pixels, 2/4 lines,

5 buttons

Interfaces

Sensor interfaces for external sensors

Label sensor:

(plug in each case 4pin M12)

Wenglor OPT242-P800 optical, NPN, 24 V, controllable sensitivity

PNP/NPN, 24 V Alternative label sensor:

Product sensor:

APSF-sensor (Rotary encoder):

PNP/NPN, 24 V single-phase/two-phase,

PNP/P-P, 24 V, max.

20 kHz

PNP, 24 V Stock sensor:

Internal sensor interfaces:

Material unwinder

Pressure roller

Dancer arm

Light barrier not used

PLC interface bi-phase light barrier encoder

Sub D15, optically insulated, optionally via two

8-pin M12 (separate inputs/outputs in each case)

Outputs:

Inputs:

4x PNP, 24 V, a maximum of 500 mA/channel, total permissible output current: 1500 mA

3x PNP/NPN, 24 V

Data interfaces:

Serial:

Ethernet:

USB:

CF card:

Control panel interface:

RS232C (Sub-D9), max. 115 200 Baud

10/100 BaseT (RJ45)

Device V1.1 (USB B),

‘Full speed’ operating mode, 12 MBit/s

Slot for 1 CompactFlash card

RS 485 (Mini DIN 6 connection) for remote control

Internal Interfaces

RFID

Applicator Interface

Connector for additional motor driver

6) Not yet available

Connection for RFID read/write unit (special equipement)

Connection for Applicator

Interface (AI) board (special equipement) not used

Status messages, test functions, product profiles

Automatic halt, if

Test functions:

Status indicators:

Storage locations for product profiles:

... the label roll is spent or no gap was found.

...the max. admissible number of missing labels is reached.

Automatic diagnostics check when switched on

Output of system data via data interface

Label counter

Operating hours counter up to 16

ALS

20x

256

2.1 O

ONTENTS

VERVIEW

Dimensions

Width x height x depth:

ALS 204

ALS 206

ALS 256

Weight:

ALS 204

ALS 206

492 x 488 x 353 mm

492 x 488 x 403 mm

36 kg

38 kg

6) Measurements without the dispensing edge bracket and dispensing edge

Environmental conditions

Operating temperature: 5 to 40°C

Humidity: 30 to 85%, (non-condensing)

72 dB(A) Noise

(at a distance of 1 m):

Protection class: IP 21

IP 65 special equipment for ALS 20X

Certificates

– CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA

– The regulation DIN EN 55022 demands for class A devices the following text to be printed in the manual:

„WARNING: This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.“

– The FCC regulation demands the following information text for class A devices:

„NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense“

Integration

Mounting positions:

Labelling positions:

Dispensing edges: side / bottom / rear top / side / bottom

V-shape

L-shape fixture 90° pivoting, for all

L-shape types

(4“ L-shape disp. edge: material width up to

100 mm only)

ALS

20x

256

ONTENTS

2.1 O

VERVIEW

2.1.6

Design models

The ALS 20X and ALS 256 label dispensers are available in two designs for differing conveyor belt directions.

Right-handed version

– The products are transported from left to right [9].

– The dispensing edge is located on the right side.

– Abbreviation: RH

Left-handed version

– The products are transported from right to left [10].

– The dispensing edge is located on the left side.

– Abbreviation: LH

The label dispenser operation described in this manual is based on the right-handed version.

The left-handed version is only taken into account if the explanations or figures of the designs differ significantly.

B

[9] Right-handed version

A ALS 20X

B Product on the conveyor belt

C Labelled product

A

C

ALS

20x

256

[10] Left-handed version

ONTENTS

2.2 O

PTIONS

2.2

OPTIONS

External control panel

– An external control panel can be connected in addition to the integrated control panel.

– An external control panel is useful if the standard control panel is difficult to access due to the position in which the unit is installed.

Fixed dispensing edge

– The dispensing edge has a fixed connection to the brackets.

– To adjust the vertical position, lift/lower the entire device.

– The slope angle can be adjusted by rotating the brackets (see the service manual for further details).

[11] External control panel

[12] Standard dispensing edge

Swivelling dispensing edge

– The position of the dispensing edge can be adjusted vertically.

– The device need not be moved to adjust the position of the dispensing edge; the device’s mounting need not be dismantled.

Spring-loaded dispensing edge

– The dispensing edge is pivoted. A torsion spring in the dispensing head presses the dispensing edge downwards and onto the surface of the product.

– Allows compensation for height differences between the products or on the product surface.

[13] Swivelling dispensing edge

[14] Spring-loaded dispensing edge

ALS

20x

256

ONTENTS

2.2 O

PTIONS

Pneumatic dispensing edge

– The dispensing edge is pivoted in the dispensing head. Compressed air presses the dispensing edge onto the surface of the product.

– Allows compensation for height differences between the products or on the product surface.

V-shape dispensing edge

– An alternative for applications which do not leave enough space for the standard dispensing edge holder, which juts out to the bottom side.

– Is attached directly to the machine

[15] Pneumatic dispensing edge

Adjustable dispensing edge holder

Enables a vertical fine adjustment of the dispensing edge towards the product without moving the machine.

[16] V-shape dispensing edge

ALS

20x

256

[17] Adjustable dispensing edge holder (pictured red resp. dark gray)

ONTENTS

2.2 O

PTIONS

Outer Diameter control sensor

The outer diameter control sensor (OD sensor) triggers a warning, if the label roll outer diameter falls below a certain, adjustable value.

Printer

– If necessary, you can mount a hot stamp printer (not available from Avery Dennison) onto the holder brackets of the dispensing edge.

– Example of use: Printing consecutive numbers onto labels.

Applicator

If it is not possible to label directly from the dispensing edge, you can fit an applicator to the label dispenser.

Various types of applicators are available that depend on the given requirements.

Simple applicators can be controlled directly via the

PLC signal interface [5G] that is available as standard.

Applicator interface

Additional board [5H]; allows almost all types of

applicators to be controlled.

Dust/Splash guard

Available only for ALS 20X.

Additional sealing of the electrical connections and of the housing fulfils the requirements of the IP65

protection class [19].

[18] OD sensor (pictured red resp. dark gray)

ALS

20x

256

[19] Dust/splash guard of the electrical connections (pictured red resp. dark gray)

ONTENTS

2.3 O

PERATING MODES

2.3

OPERATING MODES

2.3.1

Dispensing mode

This is the operating mode of the unit when switched on. You can carry out the functions listed below.

If text such as ‘Prof 5 xxxxxxxx’ is displayed instead of ‘ONLINE’:

– The ‘xxxxxxxx’ product profile (memory location 5) is activated.

– For more information, see the ‘Using product profiles’ section.

Stopping /Continuing the dispensing mode

Stopping the dispensing mode:

£ Press the button.

– Display:

ONLINE

Stopped: xxx

Continuing the dispensing mode:

£ Press the button.

Changing the counter reading

£ Set the counter reading using the MACHINE SETUP >

Dispense counter function.

Starting the unit in configuration mode

To start the unit in configuration mode:

£ Set MACHINE SETUP > Turn-on mode to ‘Offline’.

Counting labels backwards

To count dispensed labels backwards from a starting value to zero:

£ Set

LABEL SETUP > Stop count. mode

to ‘Enabled’.

£ Use the

LABEL SETUP > Label stop quan.

function to define the starting value.

A

STATUS

Online

Labels

–

292

+ – +

ALS

20x

256

[20] Control panel in dispensing mode (292 labels dispensed)

A Explanation of buttons in dispensing mode

ONTENTS

2.3 O

PERATING MODES

Online settings

The machine is in dispensing mode.

To switch to the online settings mode:

£ Press the button.

– The display shows the dispensing speed [21A] and the start offset [21C].

– The button assignments are as shown on the

buttons.

– You can increase (‘+’ button) or lower (‘–’ button) both settings in the dispensing mode

[21D].

Dispensing speed:

– Setting range:

ALS 204: [2.0…40.0] m/min

ALS 206: [2.0…30.0] m/min

– Display fix: The dispensing speed is constant.

– Display var: The dispensing speed automatically adjusts to the speed of the conveyor belt (‘speed adaption’).

Start offset:

– Setting range: [0.0…999.9] mm

– The start offset indicates the distance between the product sensor and the dispensing edge.

Dispensing manually

– To manually trigger the dispensing of individual labels:

£ Press the button.

– Dispensing speed: As specified in the setting (see above).

To switch back to dispensing mode:

£ Press the buttons + .

A B

STATUS

Speed

12.2 fix

–

Offset

0.0

+ – +

C

D

E F G H

[21] Control panel in the online settings mode

A Dispensing speed display (here: 12.2 m/min constant)

B Dispense label button

C Start offset display (here: 0 mm)

D Explanation of buttons in online settings mode

E Button to lower dispensing speed

F Button to increase dispensing speed

G Button to lower start offset

H Button to increase start offset

ALS

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256

ONTENTS

2.3 O

PERATING MODES

2.3.2

Configuration mode

The machine is in dispensing mode.

Switching to configuration mode:

£ Press the button twice.

– Display:

OFFLINE

£ Press the button.

– Display:

LABEL SETUP

– LABEL SETUP is the name of the first menu that is currently active.

– In configuration mode, the button assignments are as shown below the buttons.

Function of the double-arrow button

To dispense individual labels:

£ Press the button briefly (less than two seconds).

– Dispensing speed: As specified in the configuration;

‘Speed Adaption’ is not active.

To automatically calibrate the label length:

£ Hold down the button for a while (longer than two seconds).

Menus

In configuration mode, you have access to several menus providing a fixed sequence of functions that can be carried out.

You can set the unit so that some of the menus are not shown.

Figure [22] shows the button functions for switching

between the individual menus and for leaving them.

A

STATUS

OFFLINE

– + – +

LABEL SETUP

MACHINE SETUP

INTERFACE. PARA

I/O BOARD

APPLICATOR PARA

SERVICE/DIAGNOS.

B

C

SERVICE DATA

[22] Menu selection and button functions in configuration mode.

A Button for triggering a dispensing procedure and for starting the measurement of lengths.

B Explanation of buttons in configuration mode

C Menus

ALS

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256

2.3 O

ONTENTS

PERATING MODES

Functions

Every submenu contains functions for setting the unit controls.

Figure [23] shows the button functions for changing

settings using the MACINE SETUP > Language function as an example.

MACHINE SETUP

Store Prod.Prof.

23x

MACHINE SETUP

Language

English

A

Language

German

[23] Button functions for setting the MACHINE SETUP >

Language function.

A Button to ‘Accept changes’

B Button to ‘Cancel changes’

B

ALS

20x

256

2.4 F

ONTENTS

UNCTION DESCRIPTIONS

2.4

FUNCTION DESCRIPTIONS

2.4.1

Function overview

LABEL SETUP

Load prod. profil

Dispense speed

Slew speed

Label pitch

Lab. stop offset

Start offset

Product length

Miss. label tol.

Stop count. mode

Label stop quan. 1)

MACHINE SETUP

Store prod.prof.

Del. prod.profil

Sensor Adjust

Dispense counter

Factory settings

Parameter to CF

Auto Sensor Adj.

INTERFACE PARA

> EASYPLUGINTERPR

Interface

Spooler mode

Printer ID no.

Spooler size

Interface delay

Sensor Adjust

Speed Adaption

Encoder Type

Encoder Resol.

> COM1 PORT

Baud rate

No. of data bits

Parity

Encoder Diameter Stop bits

Tandem Operation Data synch.

Tandem Synch.

Tandem Distance

Frame error

Light sens. type

Labelsen. In.Typ

> NETWORK PARAM.

IP Addressassign.

PLC INTERFACE

End dispense mod

Disp. end delay

Disp. end time

APPLICATOR PARA

Applicator type

Apply mode

Blow on time

Restart delay

Position timeout

Start error stop

Act. apl.interf.

Startsen. In.Typ

Start disp. mode

Start error stop

Turn-on mode

Language

Access authoriz.

Material end err

OD Sensor

IP address

Net mask

Gateway address

Port address

Ethernet speed

MAC Address

SNMP Agent

FTP server

WEB server

WEB display refr

DHCP host name

1) Appears only when LABEL SETUP > Stop count. mode = ‘Enabled’

[24] Function menu ALS 20X and ALS 256 – Part 1.

ALS

20x

256

ONTENTS

2.4 F

UNCTION DESCRIPTIONS

SERVICE/DIAGNOS. SERVICE DATA

Sensor Test

(continued)

> MODULE FW VERS.

> MEMORY DATA

Compactflashtest

Test functions

System version Ram memory size

Flash mem size

> OPERATIONAL DATA Default values

Service operations

Material feed

Dispensing cycl.

Operation time

> POWER SUPPLY DATA

Type

> CPU BOARD DATA

CPU identifier

PCB Revision

FPGA version

MAC Address

Serial number

Production date

PCB part number

Board part numb.

> DISPLAY DATA

Remote Disip. vers

> CF CARD SLOT

Card in slot

> PERIPHERAL DATA

Applicator int.

1) Only with integrated applicator interface.

[25] Function overview in the ALS 20x menu – Part 2.

ALS

20x

256

2.4 F

ONTENTS

UNCTION DESCRIPTIONS

2.4.2

Notes on function descriptions

These operating instructions only describe those functions that are necessary for operating an ALS 20x that has been configured and set up. These functions are highlighted in grey in the function overview.

Only qualified service technicians may change the settings of the other functions. These functions are described in the service manual.

The settings range or the individual settings for a function are shown in square brackets.

– The default value is italicised for functions that have individual settings.

– Settings that consist of several words are shown in quotation marks.

Start offset function:

– Distance between the product sensor and the top of the dispensing plate

– Setting range: [15.0…999.9] mm; default: 15.0

Product length function:

– Setting range: [0.0…1999.9] mm; default: 0.0

Miss. label tol. function:

– Missing label tolerance

– The maximum permissible number of successive missing labels on the label strip

– Setting range: [0…10] mm; default: 1

Stop count. mode function:

– Settings: [enabled, disabled]

Enabled: Dispenser counter counts backwards, starting with the value that has been set using the

MACHINE SETUP > Dispense counter function. When the counter reaches zero, no further labels are dispensed.

Disabled: The dispenser counter counts forwards, which means that the dispenser counter is incremented with each label that is dispensed.

2.4.3

LABEL SETUP menu

Load prod. profil function:

– Loads product profiles from the internal database.

– Product profiles contain product-specific settings.

– You can select a maximum of 16 product profiles.

– You can only select product profile numbers that have profiles already stored for them.

Dispense speed function:

– The speed at which the label is dispensed

– Setting range:

ALS 204: [0.0…40.0] m/min; default: 10.0

ALS 206: [0.0…30.0] m/min; default: 10.0

ALS 256: [0.0…50.0] m/min; default: 10.0

Slew speed function:

– Feed speed during initialisation

– Setting range:

ALS 204: [0.0…40.0] m/min; default: 1.0

ALS 206: [0.0…30.0] m/min; default: 1.0

ALS 256: [0.0…50.0] m/min; default: 1.0

Label pitch function:

– Label pitch = label length+space

– Setting range: [5.0…600.0] mm

Lab. stop offset function:

– Stop position of the label on the dispensing plate

– Setting range: [0.0…999.9] mm; default: 20.0

2.4.4

MACHINE SETUP menu

Start error stop function:

– Determines how the machine responds in the event of a product start error. A product start error occurs when a new start signal arrives before the current dispensing cycle has ended.

– Settings: [On, Off]

On: Start errors are issued. If a start error occurs, the device stops and displays a relevant error message.

Off: Start errors are ignored.

Turn-on mode function:

– The operating mode of the unit after it is turned on.

– Settings: [Online, Offline]

Online: Dispensing mode

Offline: Configuration mode

Language function:

– Language of the displayed text

– Settings: [English, French, German, Spanish,

Italian, Dutch, Danish]

ALS

20x

256

2.4 F

ONTENTS

UNCTION DESCRIPTIONS

2.4.5

SERVICE DATA menu

If the displayed text is longer than the line length of the display:

£ Press the button to move the text to the left.

£ Press the button to move the text to the right.

> MODULE FW VERS. submenu

System version function:

– Shows the firmware version of the labeller

> OPERATIONAL DATA submenu

Service operations function:

– Displays the number of service operations that have

– been implemented.

Increment the counter using the

SERVICE/DIAGNOS. > Service

function.

– Maximum number: four billion

Material feed function:

– Displays the entire material feed, in other words, the

‘distance covered’ by the drive roller.

– Maximum number: four billion metres

Dispensing cycl. function:

– Counts the number of dispensed labels.

Operation time function:

– Displays the entire on-time

>POWER SUPPLY DATA submenu

Type function:

– Displays the type of power supply

MAC Address function:

– Displays the MAC address, which is a fixed and unique board address for the Ethernet interface and is programmed by the manufacturer of the board.

Serial number function:

– Displays the serial number that is programmed by the board manufacturer.

Production date function:

– Displays the production date of the CPU board

PCB part number function:

– Displays the part number of the unpopulated board.

Board part numb. function:

– Displays the part number of the populated board

> DISPLAY DATA submenu

Remote Disp.vers function:

– Displays the version of the external operator panel

> CF CARD SLOT submenu

Card in slot function:

– Tests whether the CF card is inserted in the device’s card slot.

– If the result is ‘Yes’, then the CF card is in the slot.

– If the result is ‘No’, then there is no CF card in the slot.

> PERIPHERAL DATA submenu

Applicator int. function:

– The function is only available when an applicator interface is integrated.

– Displays the firmware version of the applicator interface.

> CPU BOARD DATA submenu

CPU identifier function:

– Displays the identification of the processor in use.

PCB Revision function:

– Displays the layout revision and the part number of the CPU board.

FPGA version function:

– Displays the FPGA version.

>MEMORY DATA submenu

Ram memory size function:

– Displays the amount of RAM available.

Flash mem size function:

– Displays the amount of Flash memory available.

Default values function:

– Values that are used for a factory reset (standard or

‘User defined’, s

ee

MACHINE SETUP > Default values

).

ALS

20x

256

ONTENTS

3.1 E

LECTRICAL CONNECTIONS

E F O R E O P E R A T I O N

3.1

ELECTRICAL CONNECTIONS

3.1.1

Power supply connection

WARNING!

This machine operates using mains voltage!

Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns.

£ Make sure that the device is switched off before you connect the power cable.

£ (ALS 20X)Only operate the device with the mains voltage set on the voltage selector switch.

£ (ALS 20X) Ensure that the unit is set to receive the mains voltage supplied by your electricity provider.

£ (ALS 256) Only operate the device using the system voltage indicated on the nameplate.

£ Only connect the unit to a grounded power socket fitted to authorised standards.

£ The power cable should not be more than

3 m long.

The device is only completely disconnected

from the mains if the power cable is unplugged. Therefore:

£ Make sure the power supply socket is accessible.

£ In case of emergency, switch off the device and disconnect the power cable!

A

[26] Power supply (A) on the ALS 20X

ALS

20x

256

3.1 E

ONTENTS

LECTRICAL CONNECTIONS

Checking the power supply setting

ALS 256: A power supply setting is not required.

The ALS 20X Label Dispenser is suitable for operation with a power supply of 230 V (AC) or

110 V (AC).

If you are unsure of what mains voltage your local electricity supplier provides, refer to a qualified service technician.

Check to see that the voltage that has been set conforms to the local mains voltage.

Switch setting

115

230

Permissible mains voltage

100–120 V (AC)

200–240 V (AC)

[28] Permissible mains voltages for both positions on the voltage selector switch.

Changing the voltage setting:

Make sure that the power cable is disconnected.

Slide the switch [27A] to the respective

opposite position.

– Insert a small screwdriver into the groove

[27B]

and move the red insert horizontally to the opposite stop

position (to the left in Figure

[27]).

Connecting the power cable.

Make sure that the power switch [29A] is set to ‘O’

(off).

£ Using the supplied power cable, plug the unit into a socket connected to the mains supply.

For more information on fuses, see section

“Replacing fuses” on page 47.

A B

[27] Voltage selector switch on the ALS 20X (set to 230 V in the figure)

A

B

ALS

20x

256

[29] Power cable (B) plugged in.

3.1 E

ONTENTS

LECTRICAL CONNECTIONS

3.1.2

Connecting sensors

£ Check whether the required sensors are connected

before turning on the unit [30].

The minimum required sensors:

– Label sensor (installation location: dispensing edge)

– Product sensor (installation location: conveyor belt)

Additional optional sensors:

– Rotary encoder (required for speed adaption)

– External outer diameter checking sensor (provides advance warning of the end of a label roll)

– Alternative label sensor; for example, capacitive sensor, used to detect transparent labels.

You can find further information regarding suitable sensor types, pin assignments, and so on in the service manual.

A B C D

F

[30] Sensor connectors:

A Label sensor

B Product sensor

C Optional: Rotary encoder

D Optional: Roll diameter check

E (ALS 20x) Optional: Alternative label sensor

F (ALS 256) Optional: Alternative label sensor

E

ALS

20x

256

ONTENTS

3.2 I

NSERTING LABEL MATERIAL

3.2

INSERTING LABEL MATERIAL

3.2.1

Prerequisites

– The label dispenser is turned off at the main

switch [31A] (switch set to ‘O’).

£ Check that the safety installations are working properly.

£ Inspect the machinery for any visible damage.

Report any defects immediately.

£ Remove any unnecessary materials and objects from the operating area of the unit.

£ Make sure that only authorised persons are within the operating range of the machine.

£ Use the required personal protective equipment correctly; forexample, wear a hairnet, safety glasses.

[31] Main switch on the housing.

A

ALS

20x

256

ONTENTS

3.2 I

NSERTING LABEL MATERIAL

3.2.2

Inserting a label roll

WARNING!

Risk of injury due to moving and rapidly rotating parts!

£ Before inserting the label roll, ensure that the device is turned off at the main switch.

£ Do not under any circumstances turn the device on before the label strip is threaded in completely.

Removing spent backing paper

Assuming backing paper has gathered on the rewinder

[32A] :

Press the release button [32B].

– The tensioning mechanism of the rewinder is slackened.

£ Remove the rewound backing paper.

Removing glue residue

£ If necessary, clean the following components:

– Dispensing plate

– Deflection rollers

– Drive rollers

– Pressure roller

£ Follow the directions provided in section

“Maintenance and cleaning” on page 47.

Inserting a new label roll

Push the material roll [33A] onto the unwinder as far

as it will go.

Rotate the rotary knob [33B] in a clockwise direction

until the label roll sits tightly.

£ Run the label strip around the dancer arm as shown

in the figure [33C].

C

A

[32] A Rewound backing paper

B Release button

C Backing paper path

B

ALS

20x

256

[33] Inserting the material roll – Part 1.

ONTENTS

3.2 I

NSERTING LABEL MATERIAL

3.2.3

Threading the label roll

Threading guide

ALS

20x

256

A

[34] Threading guide for label rolls with labels facing outwards.

A Right-handed version B Left-handed version

B

A

[35] Threading guide for label rolls with labels facing inwards.

A Right-handed version B Left-handed version

B

ONTENTS

3.2 I

NSERTING LABEL MATERIAL

Threading the label roll at the dispensing edge

£ Unroll around 1 m of label strip and remove the labels from it.

£ Pass the backing paper around the first deflection

roller [36A] and through the slot in the sensor [36B].

£ Feed the backing paper under the pressure roller

[36C] to the dispensing plate [36D].

£ Feed the backing paper around the dispensing plate

to the second deflection roller [36E].

A

B

C

E

[36] Path of the label strip at the dispensing edge.

A 1st deflection roller

B Label sensor

C Pressure roller

D Dispensing plate

E 2nd deflection roller

D

ALS

20x

256

ONTENTS

3.2 I

NSERTING LABEL MATERIAL

Threading the label roll onto the drive roller

£ Open the pressure roller. To do so, rotate the lever

[37D] in a clockwise direction.

£ Feed the backing paper around the deflection roller

[37B], drive roller [37C] and the dancer arm [37A].

£ Close the pressure roller. To do so, rotate the lever until it snaps in noticeably.

A

D

[37] Open the pressure roller.

C

B

ALS

20x

256

Fastening the label roll to the rewinder

£ Clamp the backing paper to the rewinder as shown

and tighten it [39].

£ Manually rotate the rewinder by one turn.

[38] Close the pressure roller.

[39] Fastening the backing paper to the rewinder.

ONTENTS

3.3 M

ECHANICAL SETTINGS

3.3

MECHANICAL SETTINGS

3.3.1

Adjusting the unwinder’s core diameter

Tool:

– 3 mm hexagon (Allen) screwdriver

The unwinder can be adjusted with core adapters [40B]

to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter:

– 38.1 mm (1”) core

Unscrew the screws [40A] (3 for each adapter) and

remove the adapters.

– 76.2 mm (3”) core

Screw on the adapters, as is shown in Figure [40].

– 101.6 mm (4”) core

Screw on the adapters, as is shown in Figure [41].

A

B

[40] Core adapter positions for a core diameter of 76.2 mm.

ALS

20x

256

3.3.2

Positioning the pressure roller

Open the pressure roller [42B]. To do so, rotate the lever [42C] until the roller snaps up.

Release thumb screw [42A].

£ Align the pressure roller over the backing paper so that it is centred.

£ Close the pressure roller.

£ Screw the thumb screw tight.

[41] Core adapter positions for a core diameter of 101.6 mm.

B

C

A

[42] Setting the position of the pressure roller (B).

3.3 M

ONTENTS

ECHANICAL SETTINGS

3.3.3

Positioning the label sensor

£ Release the thumb screw.

£ Position the sensor along the axle in such a way as to allow it to register the spaces between the labels.

The LED [43A] lights up when the sensor is

positioned over a label.

B

A

[43] Label sensor from Wenglor, model OPT242-P800

ALS

20x

256

ONTENTS

4.1 S

TART

UP AND SHUTDOWN

P E R A T I O N

4.1

START-UP AND SHUTDOWN

4.1.1

Turning on the unit

Set the main switch [44A] of the unit to ‘I’ (On).

– The following messages are displayed during the start process:

ALS204 RH:

V 1.00

(machine type and firmware version)

Memory:

Flashcard

16 MB

48 MB

(the machine’s RAM, as well as the CF card’s memory, if a card is inserted)

ONLINE

Label 0

– Once switched on, the ALS 20x is in dispensing mode; in other words, triggering the product sensor will cause a label to be dispensed.

– You can find more information on the dispensing mode in the section “Spendebetrieb” on page 18.

4.1.2

Starting label dispensing

[44] Main switch (A) of the ALS 20x

Dispensing with a product sensor

Once switched on, the ALS 20x is in dispensing mode; this means that triggering the product sensor will cause a label to be dispensed.

Prerequisites:

– The label length must be specified.

– The product sensor must be connected.

– The sensors must be configured correctly

(PNP/NPN).

Dispensing without a product sensor

It is also possible to trigger the dispensing process without a product sensor:

– The machine is in dispensing mode:

£ Press the button.

– The machine is in configuration mode:

£ Press the button briefly (less than two seconds).

A

ALS

20x

256

ONTENTS

4.1 S

TART

UP AND SHUTDOWN

4.1.3

Stopping the dispensing process

– The machine is in dispensing mode:

£ Press the button.

– Display:

ONLINE

Stopped: xxx

– The dispenser stops.

ALS

20x

256

ONTENTS

4.2 C

ONFIGURATION AND MONITORING

4.2

CONFIGURATION AND MONITORING

4.2.1

Function menu settings

Label pitch

£ Switch to configuration mode

Calibrating the label pitch automatically:

£ Hold down the button for a while (longer than two seconds).

Or: Enter the label pitch manually:

Measure the label pitch [45C].

£ Call the LABEL SETUP > Label pitch function.

£ Enter the measured value in millimetres.

C

[45] A Label web

B Label

C Label pitch

Label stop position

Prerequisites:

– The label length must be specified.

The next label to be dispensed waits in the label stop position. Here it is useful if the label protrudes over the

dispensing edge a little [46].

ALS 20X and ALS 256 labellers are preconfigured for use with the supplied label sensor. If this sensor is employed, the label stop position setting will only require minimal correction.

Correcting the default setting:

£ Call the

LABEL SETUP > Lab. stop offset function.

£ Increase the value to increase the overhang or lower the value to reduce the overhang.

The value ‘0’ will cause the label to stop with its front edge directly under the label sensor.

The front edge of the next label to be dispensed should be flush with the dispensing edge:

Enter the distance [46A] between the label sensor

and the dispensing edge.

The front edge of the label to be dispensed should overhang:

£ Add the length of the overhang to the distance between the label sensor and the dispensing edge.

[46] Label stop position (A)

A B

ALS

20x

256

ONTENTS

4.2 C

ONFIGURATION AND MONITORING

Dispensing speed

You can set the dispensing speed to a fixed value or you can configure it to automatically adjust to the speed of the conveyor belt (speed adaption). The second option requires you to connect a rotary encoder that measures and relays the conveyor speed to the dispenser.

Configuring a fixed value:

£ Use the two left buttons to set the speed in

dispensing mode (online settings) (see “Online settings” on page 22).

Or use the function menu settings:

£ Call the LABEL SETUP > Dispense speed function and set the speed you require.

Configuring speed adaption:

£ Turn the function on by setting MACHINE SETUP >

Speed Adaption to ‘Yes’.

£ Set MACHINE SETUP > Encoder Resol. and

MACHINE SETUP > Encoder Diameter as appropriate for the employed rotary encoder.

– See the service manual for information on suitable rotary encoders.

ALS

20x

256

4.2 C

ONTENTS

ONFIGURATION AND MONITORING

Label position on the product

Prerequisites:

– The label length must be specified.

– The label stop position must be set.

Configuration in dispensing mode:

£ Use the two right buttons to set the start offset (see

“Online settings” on page 22).

Or use the function menu settings:

£ Call the LABEL SETUP > Start Offset function and set the start offset.

– The label should be flush with the front edge of the product:

£ Enter the distance between the product sensor and

the dispensing edge [47A].

[47] Distance between the product sensor (left) and the dispensing edge (right).

ALS

20x

256

– The label should be stuck at a distance from the front edge of the product:

Increase the start offset by the distance [48A] to the

product’s front edge.

[48] Distance (A) between the label and the product’s front

4.2 C

ONTENTS

ONFIGURATION AND MONITORING

4.2.2

Monitoring functions

While in dispensing mode, an electronic controller monitors the following functions:

Missing labels

A label missing from the label roll does not normally affect the dispensing operation, because the label feed continues until a label’s edge passes under the label sensor.

Nonetheless, it can be important that missing labels are reported. By configuring the function LABEL SETUP >

Miss. label tol.

, you can specify whether an error message is triggered after one or several missing labels.

Material tear

If the material path tears, one of these two messages appears:

Status num:

Material end

5002

Status num:

Rewinder control

5140

– Which message appears depends on where the material path is torn.

– The machine stops.

£ Press the button.

Material end

The following message appears when the material roll is empty:

Status num:

Material end

5002

– The machine stops.

£ Press the button to delete the message.

£ Remove the rewound backing paper.

Insert a new material roll (see “Inserting label material” on page 32).

ALS

20x

256

4.3 U

ONTENTS

SING PRODUCT PROFILES

4.3

USING PRODUCT PROFILES

4.3.1

What are product profiles?

Product profiles are memory locations that can store all the settings for the machine controls. For recurring production jobs, they allow you to quickly set the machine to the respective product.

– Number of memory locations: 16

– The memory locations are numbered. In addition, you can also enter a text identifier for each memory location (with a maximum of eight alphanumeric characters).

4.3.2

Loading a product profile

CAUTION!

Incorrect settings may lead to production problems and damage both the unit and the equipment.

£ Only staff who are qualified and specially trained should set up product databases.

£ Call the LABEL SETUP > Load prod. profil function.

– The following message appears when no memory location is occupied:

Load prod. profil

No setup avail.

– Only occupied memory locations are displayed.

– When memory locations are occupied, the memory location that was loaded last is displayed first:

Load prod. profil

Prof 1 xxxxxx

Above example: The profile with the ‘xxxxxx’ text identifier has been stored at the first memory location.

£ Press the or the button until the profile you require appears.

£ Press the button to load the profile.

– The unit restarts afterwards.

– Display after the restart:

Prof 1 xxxxxx

Label 0

(in dispensing mode, ‘ONLINE’ is replaced by the current profile name).

4.3.3

Storing a product profile

Selecting the memory location

£ Call the MACHINE SETUP > Store prod.prof.

function.

– Display shown when all memory locations are unoccupied:

Store prod.prof.

Prof 1 Product 1

– When memory locations are already occupied, the memory location that was last active is displayed:

Store prod.prof.

Prof 5*customer_xyz

– A ‘*’ occurring after the memory location number indicates that the memory location is already occupied (here by the ‘customer_xyz’ profile).

£ Press the or the button until you retrieve the memory location you require (1–16).

£ Press the button to activate the memory location.

– The profile name flashes, and you can now replace the name using any text you choose.

Entering profile names

Accepting the profile name ‘Product 1’ without changing it:

£ Press the button twice.

– The profile is saved.

– Display:

Store prod.prof.

Storing…

Changing a profile name:

£ Press the button.

– Display:

Store prod.prof.

Prof x _

– The underscore marks the active position.

£ Press the or the button to scroll through the available characters until the character you require appears.

£ Press the button to accept the character.

– The underscore jumps to the next character.

£ Enter the next character in the same way.

£ When you have entered the last character, press the

ALS

20x

256

ONTENTS

4.3 U

SING PRODUCT PROFILES

button.

– The profile is saved.

– Display:

Store prod.prof.

Storing…

– The product profile has now been saved.

4.3.4

Deleting a product profile

£ Call the MACHINE SETUP > Del. prod.profil

function.

– The memory location that was active last is displayed.

£ Press the or the button until you retrieve the memory location you require (1–16).

£ Press the button to delete the memory location:

– Display:

Del prod.profil

Clearing…

– The product profile has now been deleted.

ALS

20x

256

5.1 M

ONTENTS

AINTENANCE AND CLEANING

F T E R O P E R A T I O N

5.1

MAINTENANCE AND CLEANING

5.1.1

Replacing fuses

This section counts only for ALS 20X. The fuses at the ALS 256 cannot be replaced.

WARNING!

The machine operates using mains voltage!

Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns.

£ Make sure that the machine is switched off and the power cable is unplugged before removing the fuse insert.

CAUTION!

Risk of fire, if a wrong fuse type is inserted.

£ Only replace fuses with the type and rating specified in this manual.

The F1 and F2 fuses protect the primary side of the transformer. At any given time, only one of the two fuses is active. Which fuse is active depends on the switch setting of the voltage selector switch.

Active fuse Mains voltage

F1 230 V

F2 110 V

Switch setting

230

115

[49] Relation between the switch setting of the voltage selector switch and the active fuse.

The CPU board and sensors are protected by a separate fuse in the switching power supply that must/may never be replaced.

If either of the two fuses is not working properly, only the drive motors are affected; the display and sensors continue to operate as normal.

Tool: Screwdriver

£ Turn off the unit. Unplug the power cable.

£ Rotate the fuse holder a few degrees anticlockwise.

– The fuse holder pops up.

£ Take the fuse out of the fuse holder.

£ Replace defective fuse.

£ Replace the fuse holder and rotate it clockwise, while applying light pressure, until the slot is vertically positioned.

Required fuse type:

– T5AH 250 V

A

[50] Fuse holder (A) of the ALS 20x.

ALS

20x

256

ONTENTS

5.1 M

AINTENANCE AND CLEANING

5.1.2

Cleaning agents

Cleaning agents for rubber rollers:

– Roller cleaner, order number 98925.

If other cleaning agents are used, there is a chance the rubber may corrode.

Cleaning agents for metal deflection rollers:

– Cleaning solvent, alcohol-based solvent, isopropyl alcohol, spray for removing labels

Cleaning the unit’s housing:

– Commercially available neutral cleaning liquid

WARNING!

Cleaning solvent, alcohol-based solvent and isopropyl alcohol are highly inflammable!

£ Keep the cleaning agents, as well as any used cleaning cloths, away from open flames and other sources of ignition.

£ Do not smoke.

£ Observe the safety instructions on the container.

CAUTION!

Unsuitable cleaning agents can cause considerable damage to the unit!

£ Do not use any cleaning agent that could damage or destroy the resin surface, labelling, display, nameplates, electrical components, etc. Observe the instructions of the cleaning agent manufacturer.

£ Do not use any abrasive or plastic-corroding cleaning agents.

£ Do not use any acidic or alkaline solutions.

ALS

20x

256

ONTENTS

5.1 M

AINTENANCE AND CLEANING

5.1.3

Regular maintenance

The label dispenser is designed to be maintenance-free. However, you should service the unit regularly in order to ensure reliable long-term operating results.

Depending on operating conditions, you should perform the following at least once a week:

£ Carry out the cleaning and maintenance work described below.

Removing paper debris

£ Wipe the paper residue from the rollers and edges.

£ Clean the sensor lenses with a soft brush or cloth.

Renewal of the dust filter liner (ALS 256)

CAUTION!

An exhausted filter liner can cause the machine to overheat and to break down.

£ Replace the filter liner regularly, at least in monthly intervals.

In case of overheating the machine, the error message

„5026 MotorProtect CPU“ appears, see “List of error messages” on page 50.

Screw out the four thumb screws [51A]. Remove the filter cover [51B].

£ Replace filter liner (article no. A8697).

£ Assemble the filter cover and fix it using the thumb screws.

A

[51] Dust filter at an ALS 256.

A Thumb screws

B Filter cover

B

A

ALS

20x

256

6.1 E

ONTENTS

RROR MESSAGES

P E R A T I O N A L F A I L U R E S

6.1

ERROR MESSAGES

6.1.1

Reporting errors

When an error occurs, the machine stops immediately and displays an error message on the control panel.

Error messages are displayed as follows:

Status num:

Rewinder init20x 256

5144

[52] An example of an error message:

5144 = status number; this number makes it easier to identify the message.

‘Rewinder init’ = status text; a brief description of the error.

Error messages that are not described here may only be resolved by a qualified service technician.

When an error occurs that is not described here:

£ Press the button to delete the message.

£ Switch the device off, wait 30 seconds and then switch it on again.

If the error reoccurs:

£ Request a service technician.

Error messages that are not mentioned here are described in the service manual.

ALS

20x

256

6.1.2

List of error messages

Status Status text

5000 Bus device

5001 No gap found

5002 Rewinder full

Cause

– Device at I 2 C Bus cannot be contacted.

– In most cases, this message appears as the first in a series of two or three messages which narrow down the error more precisely.

Action to take

£ Delete the message by pressing the

-key.

£ Switch the machine off, wait 30 seconds and switch it back on.

£ If the error message

appears repeatedly, call in a servicing technician.

– The maximum limit for missing labels was exceeded ( LABEL SETUP > Miss. label tol.

– The machine is not correctly set for the type of label ( MACHINE SETUP >

Light sens. type ).

– Label length is not correctly set

( LABEL SETUP > Label distance ).

– Photoelectric label sensor is dirty.

– Photoelectric label sensor is incorrectly positioned.

– Photoelectric label sensor is not connected correctly.

– Photoelectric label sensor is defective.

– Rotary encoder is not adjusted correctly.

£ Check the points listed above and correct if necessary.

£ Press the key to confirm the error message.

£ Insert new label roll.

The (internal) roll diameter control has calculated that the end of the material roll has been reached.

[53] List of error messages

6.1 E

ONTENTS

RROR MESSAGES

Status Status text Cause

5026 MotorProtect CPU – (ALS 256) Dust filter liner exhausted.

This leads to overheating the machine.

– (ALS 20X) Voltage selection switch set faulty.

– There are some more possible causes, which require a qualified service technician to cure.

5140 Rewinder control Rewinder control

During problem-free operation, the rewind unit dancer arm only moves a minimal distance around the "control position".

This is the position the dancer arm takes up after initialisation of the machine.

Action to take

£ Renew the dust filter liner.

£ Check setting of the voltage selectioin switch.

£ If none of the above listed actions is successful, search for technical assistance.

£ Press the key.

– This reinitialises the dancer arm control; the dancer arm moves back into the control position.

5143

5145

Rewinder Stop

Material feed

– Any force applied that moves the dancer arm from its control position.

Example: The feed motor is blocked; the backing paper is not conveyed quickly enough; as a result the dancer arm is pulled upwards.

Example: The backing paper is torn; the dancer arm springs downwards.

– This message appears when the dancer arm was held against its upper stop for more than two seconds.

Effect:

Power to the rewinder motor is switched off, so that the rewinder can be turned easily by hand.

£ Press the key to confirm the error message.

This effect is helpful when installing a new label roll, because the rewinder can be turned easily.

The maximum permitted diameter

(205 mm) for the rewinder roll has been reached.

£ Remove the rewound backing paper

This error can only occur if the end of a new label roll was glued on to backing paper that had already been wound onto the rewinder.

£ Press the key to confirm the error message.

[53] List of error messages

ALS

20x

256

6.1 E

ONTENTS

RROR MESSAGES

Status

5147

5200

Status text

Tandemsynch. Init

Home position

Cause

This message can only appear during tandem operation.

– Communication between the master and slave machines is not functioning.

Action to take

£ Check tandem interface cable.

– Is it a) in place and b) correctly connected?

£ Check the settings on both machines.

– Siehe “Setting up tandem operation” auf Seite 112.

This message may appear when operating the applicator. The applicator did not reach its home position (upper end position) within the intended time-frame.

– The applicator is stuck

– Compressed air applicator: Compressed air supply interrupted or switched off

– Cable not correctly connected.

£ Remove any obstructions

£ Check compressed air connection and reconnect correctly if necessary

£ Check cable and connect correctly if necessary.

5201

6002

Touch Down

New prog. vers.

The applicator lower end position

(Touch Down) was not reached in time.

New firmware has been loaded. This is a message from the labeller that new firmware is available.

£ Press the Online button to confirm.

– All parameters are reset to their factory settings.

6031 New Parameters New firmware was loaded with the result that new functions have been added to the menu.

£ No action necessary. The message is for information only.

6207

9022

No file card

No network link

No compact flash card was found.

This status message can only appear when Ethernet address assignment is set to DHCP ( INTERFACE PARA >

NETWORK PARAM.> IP Addressassign ). The cause is almost invariably an incorrectly plugged-in network connector.

£ Check whether a compact flash card is connected. If the compact flash card was not connected until after the machine was switched on: Switch the machine off and back on again.

£ Check whether the network connector is plugged in correctly, correct if necessary.

[53] List of error messages

ALS

20x

256

ONTENTS

7.1 EU D

ECLARATION OF

ONFORMITY

P P E N D I X

7.1

EU DECLARATION OF CONFORMITY

We,

Avery Dennison Deutschland GmbH

Ohmstrasse 3

85386 Eching, Germany herewith assert that we have designed and built the device described in the following to conform with the basic safety and health requirements of the relevant EU directives.

ALS

20x

256

Name of the devices:

Device type:

Serial number:

Relevant EU directives:

Other applicable, harmonised norms, in particular:

ALS 204, ALS 206, ALS 256

Label dispenser

Consists of a sequential number (five-digit) + date code (YYMM) + ending (device name): –ALS204, –ALS206 or –ALS256

(Example: 040060309–ALS204)