Avery Dennison ALS 204 Operating Instructions Manual
Avery Dennison ALS 204 Operating Instructions Manual

Avery Dennison ALS 204 Operating Instructions Manual

Label dispenser
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O
PERATING INSTRUCTIONS
Label Dispenser
ALS
204/206
256
Edition 04/2007

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Summary of Contents for Avery Dennison ALS 204

  • Page 1 PERATING INSTRUCTIONS Label Dispenser 204/206 Edition 04/2007...
  • Page 3: Table Of Contents

    ONTENTS Please note 1.1 General notes 1.1.1 Validity and binding effect of this manual ..1 Contents ....... 1 Technical status .
  • Page 4 ONTENTS > CPU BOARD DATA submenu ... . 28 > DISPLAY DATA submenu ....28 > CF CARD SLOT submenu ....28 >...
  • Page 5: General Notes

    Validity and binding effect of this manual 1.1.1 Contents The present manual refers exclusively to the ALS 204, ALS 206 and ALS 256 label dispensers. It is written for the purpose of ensuring professional usage and calibration of the unit.
  • Page 6: Illustrations And Descriptions

    ONTENTS 1.1 G ENERAL NOTES Illustrations and descriptions 1.1.2 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.
  • Page 7: Information And Qualifications

    ONTENTS 1.2 S AFETY INSTRUCTIONS SAFETY INSTRUCTIONS Information and qualifications 1.2.1 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.
  • Page 8: Protection Against Injuries By Electrical Current

    ONTENTS 1.2 S AFETY INSTRUCTIONS Operational safety of the unit 1.2.2 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;...
  • Page 9: Protection Against Injuries By Mechanical Action

    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.
  • Page 10: Before Beginning Production

    ONTENTS 1.2 S AFETY INSTRUCTIONS Before beginning production 1.2.3 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.
  • Page 11: Safety Notes On The Unit

    ONTENTS 1.2 S AFETY INSTRUCTIONS Safety 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. The ‘Pinch Point’ warning [1] note warns you of the danger posed by the machine’s rotating parts;...
  • Page 12: Product Description

    ONTENTS 2.1 O VERVIEW R O DU C T D E SC R IPT IO N OVERVIEW Components 2.1.1 [3] ALS 204 Label Dispenser (right-handed version)
  • Page 13 ONTENTS 2.1 O 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. –...
  • Page 14: Control Panel

    ONTENTS 2.1 O VERVIEW Control panel 2.1.2 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;...
  • Page 15: Connections On The Back Of The Device

    ONTENTS 2.1 O VERVIEW Connection arrangement 2.1.3 Connections on the back of the device [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”...
  • Page 16: Sensor Connections

    ONTENTS 2.1 O VERVIEW Sensor connections PLC-IN PLC-OUT START ROTARY ENCODER LABEL 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...
  • Page 17: Mode Of Operation

    ONTENTS 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 [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.
  • Page 18: Technical Specifications

    ONTENTS 2.1 O VERVIEW Technical specifications 2.1.5 Characteristics Dispensing speed ALS 204 max. 40 m/min ALS 206 max. 30 m/min ALS 256 max. 50 m/min Labelling halt precision ±1 mm at the peeling edge: Speed control: Fixed setting or automatic...
  • Page 19: Electronics

    ONTENTS 2.1 O VERVIEW Electronics Processor: 32 Bit CPU MIPS Core RAM: 16 MB ROM: 4 MB Control panel: graphical display with 128 x 32 pixels, 2/4 lines, 5 buttons Interfaces Sensor interfaces for (plug in each case 4- external sensors pin M12) Label sensor: Wenglor OPT242-P800...
  • Page 20: Dimensions

    ONTENTS 2.1 O VERVIEW Dimensions Width x height x depth: ALS 204 492 x 488 x 353 mm ALS 206 492 x 488 x 403 mm ALS 256 492 x 488 x 403 mm Weight: ALS 204 36 kg ALS 206...
  • Page 21: Design Models

    ONTENTS 2.1 O VERVIEW Design models 2.1.6 The ALS 20X and ALS 256 label dispensers are availa- ble 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. –...
  • Page 22: Options

    ONTENTS 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 23: Pneumatic Dispensing Edge

    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 –...
  • Page 24: Outer Diameter Control Sensor

    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 25: Operating Modes

    ONTENTS 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 below. If text such as ‘Prof 5 xxxxxxxx’ is displayed instead of ‘ONLINE’: –...
  • Page 26: Online Settings

    [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’).
  • Page 27: Configuration Mode

    ONTENTS 2.3 O PERATING MODES Configuration mode 2.3.2 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.
  • Page 28: Functions

    ONTENTS 2.3 O PERATING MODES Functions Every submenu contains functions for setting the unit controls. Figure [23] shows the button functions for changing MACINE SETUP > Language settings using the an example. MACHINE SETUP function as MACHINE SETUP Store Prod.Prof. MACHINE SETUP Language Language...
  • Page 29: Function Descriptions

    ONTENTS 2.4 F UNCTION DESCRIPTIONS FUNCTION DESCRIPTIONS Function overview 2.4.1 LABEL SETUP MACHINE SETUP Load prod. profil Store prod.prof. Dispense speed Del. prod.profil Slew speed Sensor Adjust Label pitch Dispense counter Lab. stop offset Factory settings Start offset Parameter to CF Product length Auto Sensor Adj.
  • Page 30 ONTENTS 2.4 F UNCTION DESCRIPTIONS SERVICE/DIAGNOS. SERVICE DATA > MODULE FW VERS. Sensor Test Compactflashtest System version Test functions > 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...
  • Page 31: Notes On Function Descriptions

    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: –...
  • Page 32: Service Data Menu

    ONTENTS 2.4 F UNCTION DESCRIPTIONS SERVICE DATA menu 2.4.5 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.
  • Page 33: Before Operation

    ONTENTS 3.1 E LECTRICAL CONNECTIONS E FO R E O PE R AT IO N 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.
  • Page 34: Checking The Power Supply Setting

    ONTENTS 3.1 E LECTRICAL CONNECTIONS Checking the power supply setting ALS 256: A power supply setting is not re- quired. 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.
  • Page 35: Connecting Sensors

    ONTENTS 3.1 E LECTRICAL CONNECTIONS Connecting sensors 3.1.2 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: –...
  • Page 36: Inserting Label Material

    ONTENTS 3.2 I NSERTING LABEL MATERIAL INSERTING LABEL MATERIAL Prerequisites 3.2.1 – 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.
  • Page 37: Inserting A Label Roll

    ONTENTS 3.2 I NSERTING LABEL MATERIAL Inserting a label roll 3.2.2 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.
  • Page 38: Threading The Label Roll

    ONTENTS 3.2 I NSERTING LABEL MATERIAL Threading the label roll 3.2.3 Threading guide [34] Threading guide for label rolls with labels facing outwards. A Right-handed version [35] Threading guide for label rolls with labels facing inwards. A Right-handed version B Left-handed version B Left-handed version...
  • Page 39: Threading The Label Roll At The Dispensing Edge

    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].
  • Page 40: Threading The Label Roll Onto The Drive Roller

    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.
  • Page 41: Mechanical Settings

    ONTENTS 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 [40B] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter: –...
  • Page 42: Positioning The Label Sensor

    ONTENTS 3.3 M ECHANICAL SETTINGS Positioning the label sensor 3.3.3 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.
  • Page 43: Start-Up And Shutdown

    ONTENTS 4.1 S TART UP AND SHUTDOWN P E RA TIO N START-UP AND SHUTDOWN Turning on the unit 4.1.1 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)
  • Page 44: Stopping The Dispensing Process

    ONTENTS 4.1 S TART UP AND SHUTDOWN Stopping the dispensing 4.1.3 process – The machine is in dispensing mode: Press the button. – Display: ONLINE Stopped: – The dispenser stops.
  • Page 45: Configuration And Monitoring

    ONTENTS 4.2 C ONFIGURATION AND MONITORING CONFIGURATION AND MONITORING Function menu settings 4.2.1 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].
  • Page 46: Dispensing Speed

    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.
  • Page 47: Label Position On The Product

    ONTENTS 4.2 C 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”...
  • Page 48: Monitoring Functions

    ONTENTS 4.2 C ONFIGURATION AND MONITORING Monitoring functions 4.2.2 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.
  • Page 49: Using Product Profiles

    ONTENTS 4.3 U SING PRODUCT PROFILES USING PRODUCT PROFILES What are product profiles? 4.3.1 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.
  • Page 50: Deleting A Product Profile

    ONTENTS 4.3 U SING PRODUCT PROFILES button. – The profile is saved. – Display: Store prod.prof. Storing… – The product profile has now been saved. Deleting a product profile 4.3.4 MACHINE SETUP > Del. prod.profil Call the – The memory location that was active last is displayed.
  • Page 51: Maintenance And Cleaning

    ONTENTS 5.1 M AINTENANCE AND CLEANING FT ER O P ER A TIO N MAINTENANCE AND CLEANING Replacing fuses 5.1.1 This section counts only for ALS 20X. The fu- ses 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.
  • Page 52: Cleaning Agents

    ONTENTS 5.1 M AINTENANCE AND CLEANING Cleaning agents 5.1.2 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: –...
  • Page 53: Regular Maintenance

    ONTENTS 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. Depending on operating conditions, you should perform the following at least once a week: Carry out the cleaning and maintenance work described below.
  • Page 54: Operational Failures

    ONTENTS 6.1 E RROR MESSAGES PE R AT IO N AL FA IL UR E S ERROR MESSAGES Reporting errors 6.1.1 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: 5144 Rewinder init20x 256...
  • Page 55 ONTENTS 6.1 E RROR MESSAGES Status Status text Cause 5026 MotorProtect CPU – (ALS 256) Dust filter liner exhausted. This leads to overheating the ma- chine. – (ALS 20X) Voltage selection switch set faulty. – There are some more possible caus- es, which require a qualified service technician to cure.
  • Page 56 ONTENTS 6.1 E RROR MESSAGES Status Status text Cause 5147 Tandemsynch. Init – Communication between the master and slave machines is not function- ing. 5200 Home position – The applicator is stuck – Compressed air applicator: Com- pressed air supply interrupted or switched off –...
  • Page 57: Avery Dennison Deutschland Gmbh Ohmstrasse

    Relevant EU directives: Other applicable, harmonised norms, in particular: Eching, 21 March 2006 ONFORMITY 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)
  • Page 58 Avery Dennison Deutschland GmbH Ohmstrasse 3 85386 Eching Germany Phone: +49-8165-925-0 http://www.machines.averydennison.com...

This manual is also suitable for:

Als 206Als 256

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