Avery Dennison ALS 204 User Manual
Label dispenser
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- Service and installation manual (224 pages) ,
- User manual (62 pages) ,
- Operating instructions manual (58 pages)
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Summary of Contents for Avery Dennison ALS 204
- Page 1 ANUAL Label Dispenser 204/206 Edition 11 - 12/2014 - Translation of original version...
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Page 3: Table Of Contents
ONTENTS Please note 2.1.5 Technical specifications ....21 Characteristics ......21 1.1 General notes Labels . - Page 4 ONTENTS 2.4 Function descriptions Suppressing start signals ....50 Label position on the product ....50 2.4.1 Overview of functions .
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Page 5: Please Note
ENERAL NOTES LEASE NOTE GENERAL NOTES Validity and binding effect of this manual 1.1.1 Contents The complete operating manual for the ALS 204, ALS 206 and ALS 256 label dispensers consists of the following parts: Manual Target group Medium Availability... -
Page 6: Copyright
LEASE NOTE 1.1 G ENERAL NOTES Copyright 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. -
Page 7: Illustrations And Descriptions
LEASE NOTE 1.1 G ENERAL NOTES Illustrations and descriptions 1.1.2 Signs and symbols Figures Various information types are indicated in different Texts are accompanied by figures where necessary. ways within the document in order to simplify Figures are indicated using figure numbers in [square readability and comprehension. -
Page 8: Safety Instructions
LEASE NOTE 1.2 S AFETY INSTRUCTIONS SAFETY INSTRUCTIONS Information and qualifications 1.2.1 At least two people must be instructed in the unit’s usage. Qualification Enough label material must be provided for testing and instructional purposes. Ensure the required qualifications are met Ensure that only trained and authorized personnel ... -
Page 9: Follow The Instructions
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Follow the instructions Keep the product information at hand WARNING! With respect to this manual: It should be kept at the location where the unit is Safe and efficient operation of the label installed and be available to the operator. -
Page 10: Operational Safety Of The Unit
Any other type of or more extensive application will be considered non-intended use.Avery Dennison shall assume no liability for damage resulting from non- intended use of the machine. The system integrator must install the machine with suitable equipment to protect operating personnel from danger;... -
Page 11: Protection Against Injuries By Electrical Current
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Protection against injuries by electrical current WARNING! WARNING! The machine operates using mains voltage! The device is only completely disconnected Touching live electrical parts may expose from the mains if the power cable is you to hazardous electrical currents and unplugged. -
Page 12: Protection Against Injuries By Mechanical Action
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Protection against injuries by mechanical action WARNING! WARNING! Risk of injury due to moving and rapidly Tripping hazard! rotating parts! Lay the connection cable and pneumatic Maintain a safety clearance from the hoses (if fitted) so that no one can trip ... -
Page 13: Before Beginning Production
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Before beginning production 1.2.3 Due diligence of the operating company Due diligence of the user and the service technician Check that the safety installations are working properly. Ensure that the following prerequisites are fulfilled in ... -
Page 14: Warning Notes On The Unit
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Warning notes on the unit 1.2.4 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. Warning note Meaning Article no. -
Page 15: Product Description
RODUCT DESCRIPTION 2.1 O VERVIEW RODUCT DESCRIPTION OVERVIEW Components 2.1.1 ALS 256 [5] ALS 204 Label Dispenser (right-handed version) - Page 16 RODUCT DESCRIPTION 2.1 O VERVIEW A Control panel J Dispensing edge – For sending commands to the device and for – Standard: (non-adjustable) L-shaped dispensing displaying operating states and error messages. edge – An optional external control panel can also be –...
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Page 17: Control Panel
RODUCT DESCRIPTION 2.1 O VERVIEW Control panel 2.1.2 Operating LED STATUS Lights up green when the device is switched on. Online Labels Error LED – – Lights up red when an error occurs. LCD display – Displays functions, configured values, operating states and error messages. -
Page 18: Connection Arrangement
RODUCT DESCRIPTION 2.1 O VERVIEW Connection arrangement 2.1.3 Connections on the back of the device [7] Connections on the back of the device (ALS 20x) A Power supply connection For information on connecting the unit, see B Network connection (Ethernet 10/100) section “Power supply connection”... -
Page 19: Sensor Connections
RODUCT DESCRIPTION 2.1 O VERVIEW Sensor connections [8] Sensor connections on the ALS 20x (RH) PLC-IN PLC-OUT PLC-OUT PLC-IN START START ROTARY ROTARY ENCODER ENCODER LABEL LABEL CAP for 256 CAP for 256 [9] Arrangement of the sensor connections (schematic) on the LH (left figure) and RH (right figure) devices: A Product sensor B Signal outputs (optional) -
Page 20: Mode Of Operation
RODUCT DESCRIPTION 2.1 O VERVIEW Mode of operation 2.1.4 In labelling mode, the strip is first pulled from the label roll around the dancer arm [10A], which consistently maintains even tension in the label strip. The feed roller [10D] behind the dispensing edge [10C] draws the strip across the dispensing plate. -
Page 21: Technical Specifications
RODUCT DESCRIPTION 2.1 O VERVIEW Technical specifications 2.1.5 Characteristics Label sensor Dispensing speed Distance to peel edge ALS 204 max. 40 m/min L-shape dispensing ALS 206 max. 30 m/min edge: 19 mm ALS 256 max. 50 m/min V-shape dispensing edge:... -
Page 22: Electronics
RODUCT DESCRIPTION 2.1 O VERVIEW Electronics Data interfaces: Processor: 32 Bit CPU ARM926-EJ Serial: RS232C (Sub-D9), max. 115 200 Baud RAM: 128 MB Ethernet: 10/100 BaseT (RJ45) ROM: 8 MB USB: USB B (device) V1.1, Control panel: graphical display with ‘Full speed’... -
Page 23: Dimensions
TÜV -Mark Height x width x depth: – The regulation DIN EN 55022 demands for class A ALS 204 492 x 488 x 371 mm devices the following text to be printed in the ALS 206 492 x 488 x 402 mm... -
Page 24: Design Models
RODUCT DESCRIPTION 2.1 O VERVIEW Design models 2.1.6 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 [11]. – The dispensing edge is located on the right side. –... -
Page 25: Options
RODUCT DESCRIPTION 2.2 O PTIONS 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. -
Page 26: Pneumatic Dispensing Edge
RODUCT DESCRIPTION 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. [17] Pneumatic dispensing edge V-shape dispensing edge Not for ALS 256! -
Page 27: Outer Diameter Control Sensor
RODUCT DESCRIPTION 2.2 O PTIONS Outer Diameter control sensor The outer diameter control sensor [20A] (OD sensor) triggers a warning, if the label roll outer diameter falls below a certain, adjustable value. [20] OD sensor (A) 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 [21A]. -
Page 28: Capacitive Label Sensor
[23] Capacitive label sensor with bracket and cable. 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. -
Page 29: Operating Modes
RODUCT DESCRIPTION 2.3 O PERATING MODES OPERATING MODES Dispensing mode 2.3.1 This is the operating mode of the unit when switched on. You can carry out the functions listed in the sections STATUS below. Online If text such as ‘Prof 5 xxxxxxxx’ is displayed Labels instead of ‘ONLINE’: –... -
Page 30: Online Settings
– You can increase (‘+’ button) or lower (‘–’ button) both settings in the dispensing mode [25D]. Dispensing speed: – Setting range: ALS 204: [1.0…40.0] m/min ALS 206: [1.0…30.0] m/min [25 Control panel in the online settings mode ALS 256: [1.0…50.0] m/min A Dispensing speed display (here: 12.2 m/min constant) -
Page 31: Configuration Mode
RODUCT DESCRIPTION 2.3 O PERATING MODES Configuration mode 2.3.2 The machine is in dispensing mode. Switching to configuration mode: STATUS Press the button twice. – Display: OFFLINE OFFLINE – – Press the button. – Display: LABEL SETUP – LABEL SETUP is the name of the first menu that is currently active. -
Page 32: Functions
RODUCT DESCRIPTION 2.3 O PERATING MODES Functions Every submenu contains functions for setting the unit controls. Figure [4] shows the button functions for changing MACHINE SETUP > Language settings using the function as an example (English is the preset language, so you most probably don´t have to change this setting. -
Page 33: Function Descriptions
RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS FUNCTION DESCRIPTIONS Overview of functions 2.4.1 (continued) (continued) LABEL SETUP MACHINE SETUP INTERFACE PARA Load prod.profil Dispenser type Labelsen. InType >EASYPLUGINTERPR DHCP host name Gap detect. mode Store prod.prof. Startsen. In.Type Interface FTP server Dispense speed Del. - Page 34 RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS (continued) (continued) SIGNAL INTERFACE SERVICE/DIAGNOS. SERVICE DATA >MODULE FW VERS. Interface mode >AI BOARD SIGNAL Service Work place >PLC SIGNALS Applicator type Serv. data reset System version Company name End dispense mod Apply mode Sensor Test System revision Disp.
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Page 35: Notes
– The speed at which the label is dispensed highlighted in grey in the overview. – Setting range: ALS 204: [1.0…40.0] m/min; default: 10.0 Settings of functions that are not described in ALS 206: [1.0…30.0] m/min; default: 10.0 the following may only be changed by qualified ALS 256: [1.0…50.0] m/min;... -
Page 36: Machine Setup Menu
RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS MACHINE SETUP menu 2.4.4 „x labels/start“: Each start signal causes printing of x labels; x = [2…20] Store prod.prof. function: x > 3: The distance of all following labels after the – Storing a product profile, see chap. “Storing a 2nd label matches the value set in LABEL SETUP >... - Page 37 RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS An additional material end error is caused, if no unwinder rotation is detected during at least 600 mm of material feeding: Status num: 5072 Material end unw Materialend warn function: – Refers to the internal OD control. –...
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Page 38: Before Operation
EFORE OPERATION 3.1 E LECTRICAL CONNECTIONS EFORE OPERATION ELECTRICAL CONNECTIONS Power supply connection 3.1.1 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 ... -
Page 39: Checking The Power Supply Setting
EFORE OPERATION 3.1 E LECTRICAL CONNECTIONS Checking the power supply setting ALS 256: A power supply setting is not requi- red. The ALS 20X Label Dispenser is suitable for operation with a power supply of 230 V (AC) or 110 V (AC). Make sure that the power cable is disconnected. -
Page 40: Connecting The Power Cable
EFORE OPERATION 3.1 E LECTRICAL CONNECTIONS Connecting the power cable Make sure that the power switch [35A] is set to ‘O’ (off). Using the supplied power cable, plug the unit into a socket connected to the mains supply. ALS 20x with splash guard: The power cable is connected by installing the hood. -
Page 41: Inserting Label Material
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL INSERTING LABEL MATERIAL Inserting a label roll 3.2.1 WARNING! Risk of injury due to moving and rapidly rotating parts! Before inserting the label roll, ensure that the device is in offline mode. Danger of injury caused by falling label roll! Wear safety shoes. -
Page 42: Threading The Label Roll
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Threading the label roll 3.2.2 Threading guide [39] Threading guide for ALS 20x/256 with L-shape dispensing edge A Right-handed version B Left-handed version [40] Threading guide for ALS 20x/256 with V-shape dispensing edge A Right-handed version B Left-handed version *) Solid line: Path for label rolls with labels facing outwards. -
Page 43: Threading The Label Roll At The Dispensing Edge
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Threading the label roll at the dispensing edge Fixed [41] (standard) and pivotable L-Shape dispen- sing edges: Unroll around 1 m of label strip and remove the labels from it. Pass the backing paper around the first deflection ... -
Page 44: Threading The Label Roll Onto The Drive Roller
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Threading the label roll onto the drive roller Open the pressure roller. To do so, rotate the lever [44D] in a clockwise direction. Feed the backing paper around the deflection roller [44B], drive roller [44C] and the dancer arm [44A]. -
Page 45: Mechanical Settings
EFORE OPERATION 3.3 M ECHANICAL SETTINGS MECHANICAL SETTINGS Adjusting the unwinder’s core 3.3.1 diameter Tool: – 3 mm hexagon (Allen) screwdriver The unwinder can be adjusted with core adapters [47B] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter: –... -
Page 46: Positioning The Label Sensor
EFORE OPERATION 3.3 M ECHANICAL SETTINGS Positioning the label sensor 3.3.3 Release the thumb screw [50B]. Position the sensor along the axle in such a way as to allow it to register the spaces between the labels. The LEDs [50A] light up when the sensor is positioned over a gap. -
Page 47: Operation
PERATION 4.1 S TART UP AND SHUTDOWN PERATION START-UP AND SHUTDOWN Turning on the unit Dispensing without a product sensor 4.1.1 It is also possible to trigger the dispensing process without a product sensor: – The machine is in dispensing mode: Press the button. -
Page 48: Configuration And Monitoring
At maximum dispensing speed set the Lab. stop offset to at least the following value Machine Min. stop pos. ALS 204 14 mm ALS 206 8 mm ALS 256 9 mm Don´t set Lab. stop offset to the same ... -
Page 49: Dispensing Speed
PERATION 4.2 C ONFIGURATION AND MONITORING 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 [54]. ALS 20x/ALS 256 labellers are pre-configured for use with the supplied label sensor. If this sensor is employed, the label stop position setting will only require minimal correction. -
Page 50: Suppressing Start Signals
PERATION 4.2 C ONFIGURATION AND MONITORING Suppressing start signals A start signal can be prematurely triggered by the shape of the product or reflective surfaces, what can cause erroneous labelling. In case of a product causing unwanted additional start signals while the product passes the dispensing edge, those signals can be LABEL SETUP >... -
Page 51: Monitoring Functions
PERATION 4.2 C ONFIGURATION AND MONITORING Monitoring functions 4.2.2 While in dispensing mode, an electronic controller monitors the following functions: Material end / Roll diameter (OD = outer diameter) To enable a quick renewal of the material roll, the machine can alarm the operator before the end of the material roll is reached. -
Page 52: Missing Labels
PERATION 4.2 C ONFIGURATION AND MONITORING If an error message occurs: – The machine stops. Press the button to delete the message. Remove the rewound backing paper. Insert a new material roll (see “Inserting a label roll” on page 41). -
Page 53: Rewinder Full
PERATION 4.2 C ONFIGURATION AND MONITORING Rewinder full If the diameter of the rewound backing paper [61A] exceeds the admissible diameter (202 mm), the following message appears: Status num: 5064 Rewinder full Remove the rewound backing paper. (See chap. “Removing spent backing paper” on page 41). -
Page 54: Using Product Profiles
PERATION 4.3 U SING PRODUCT PROFILES USING PRODUCT PROFILES What are product profiles? – Display after the restart: 4.3.1 Prof 1 xxxxxx Product profiles are memory locations that can store all Labels the settings for the machine controls. For recurring production jobs, they allow you to quickly set the (in dispensing mode, ‘ONLINE’... -
Page 55: Deleting A Product Profile
PERATION 4.3 U SING PRODUCT PROFILES 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. -
Page 56: After Operation
FTER OPERATION 5.1 M AINTENANCE AND CLEANING FTER OPERATION MAINTENANCE AND CLEANING Replacing fuses Tool: Screwdriver 5.1.1 This section counts only for ALS 20X. The fuses at the ALS 256 cannot be replaced. Turn off the unit. Unplug the power cable. ... -
Page 57: Cleaning Agents
FTER OPERATION 5.1 M AINTENANCE AND CLEANING Cleaning agents 5.1.2 Cleaning agents for rubber rollers [64A]: – Roller cleaner, order number 98925. If other cleaning agents are used, there is a chance the rubber may corrode. Cleaning agents for metal deflexion rollers [64B]: –... -
Page 58: Regular Maintenance
FTER OPERATION 5.1 M AINTENANCE AND CLEANING Regular maintenance 5.1.3 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. Removing paper debris Depending on operating conditions, you should perform the following at least once a week: Wipe the paper residue from the rollers and edges. -
Page 59: Operational Failures
PERATIONAL FAILURES 6.1 S TATUS MESSAGES PERATIONAL FAILURES STATUS MESSAGES Types of status messages List of warnings 6.1.1 6.1.2 Error messages Displayed text Meaning When an error occurs, the machine stops immediately Productstartwarn New start signal during the and displays an error message on the control panel. dispensing operation. -
Page 60: List Of Error Messages
PERATIONAL FAILURES 6.1 S TATUS MESSAGES List of error messages 6.1.3 Status Status text Cause Action to take 5000 Bus device – Device at I C Bus cannot be Delete the message by pressing the contacted. -key. – In most cases, this message appears Switch the machine off, wait 30 ... - Page 61 PERATIONAL FAILURES 6.1 S TATUS MESSAGES Status Status text Cause Action to take 5072 Material end unw – Occurs during operation with Check the material feeding; if activated internal OD control. necessary, replenish the material – The message appears, if no rotation roll.
- Page 62 PERATIONAL FAILURES 6.1 S TATUS MESSAGES Status Status text Cause Action to take 5145 Rewinder full This error can only occur if the Remove the rewound backing paper end of a new label roll was glued Press the key to confirm the ...
- Page 63 PERATIONAL FAILURES 6.1 S TATUS MESSAGES Status Status text Cause Action to take 6207 No file card No compact flash card was found. 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.
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Page 64: Ec Declarations
Models ALS 204 / ALS 206 / ALS 256 General designation Label dispenser... -
Page 65: Ec Declaration Of Incorporation
2006/42/EG annex II A. Models ALS 204 / ALS 206 / ALS 256 General designation Label dispenser Consists of a consecutive number (5 digits) + date code (YYMM) + Serial number end (unit designation -ALS204, -ALS206 or -ALS256). -
Page 66: Appendix Regarding The Declaration Of Incorporation
Appendix regarding the Declaration of Incorporation List of the essential health and safety requirements applied and fulfilled for the product named in the declaration of incorporation, relating to the design and construction of machinery. Number Not appli- Designation Fulfilled Remark Annex I cable General remarks... - Page 67 EC D ECLARATIONS Number Not appli- Designation Fulfilled Remark Annex I cable 1.5.4. Errors of fitting 1.5.5. Extreme temperatures 1.5.6. Fire 1.5.7. Explosion 1.5.8. Noise 1.5.9. Vibrations 1.5.10. Radiation 1.5.11. External radiation 1.5.12. Laser radiation 1.5.13. Emissions of hazardous materials and substances 1.5.14.
- Page 68 Avery Dennison Deutschland GmbH Ohmstraße 3 85386 Eching Germany | Tyskland | Alemania | Saksa | Allemagne | Germania | Duitsland | Alemanha | Герма ́ ния +49-8165-925-0 http://www.monarch.averydennison.com...
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