Avery Dennison ALS 230 User Manual
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Avery Dennison ALS 230 User Manual

Avery Dennison ALS 230 User Manual

Avery dennison label maker user manual
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  • Page 3: Table Of Contents

    Operators Manual ALS 230 Contents 1. Important Notes... 4 1.1 Overview... 4 1.1.1 Manufacturer... 4 1.1.2 Copyright... 4 1.2 Safety... 5 1.2.1 General Safety Notes ... 5 1.2.2 Warning Notes in the Text ... 5 1.2.3 Operator’s duty of care ... 6 1.2.4 Concrete security regulations and symbols used ...
  • Page 4 Operators Manual ALS 230 4. Operation ... 23 4.1 Safety recommendation ...23 4.2 Inserting label material...24 4.3 Initialise new label material ...25 4.4 Control of dispense unit ...26 4.4.1 Dispenser Menu selection...26 4.4.2 Missing label function and web breaks ...26 4.4.3 Display and data input...26...
  • Page 5 Operators Manual ALS 230 8.4 EMI ... 66 8.5 Electronic diagrams ... 67 9. Errors and warnings ... 71 9.1 Dispenser error messages ... 71 9.2 Dispenser warnings ... 73 10. Technical Specification... 75 10.1 Technical Information ... 75 10.2 Application specification ... 76 10.3 APSF- Sensor Specification (Optional function) ...

  • Page 6: Important Notes

    1. Important Notes 1.1 Overview The AVERY ALS 230 is a fully automatic labeller. Handling is very easy and can be learned with a minimum of training. For operation, only a few adjustments are necessary. The machine is controlled by a microprocessor and because of its programmable functions, it can be used in many applications.

  • Page 7: Safety

    Operators Manual ALS 230 Avery Dennison Corporation is given or implied. All other brand and product names are the trademark of their respective owners. 1.2 Safety 1.2.1 General Safety Notes In order to avoid any risk of injury due to squeezing between the fixed dispensing edge and the passing product, it may be necessary to add a protection cover in front of the dispensing edge.

  • Page 8: Operator's Duty Of Care

    Operators Manual ALS 230 1.2.3 Operator’s duty of care The machine was designed and constructed taking into account a hazard analysis and after careful selection of the harmonised standards to be observed, as well as other technical specifications. Thus, it corresponds to the state of the art and allows the highest possible degree of safety during operation.

  • Page 9: Concrete Security Regulations And Symbols Used

    Operators Manual ALS 230 1.2.4 Concrete security regulations and symbols used In the following operating instructions, concrete security regulations are indicated in order to point out the remaining risks which cannot be avoided when operating the machine. These remaining risks include danger to •...

  • Page 10: Security Measures During Normal Operation

    Operators Manual ALS 230 1.2.5 Security measures during normal operation The machine may only be operated by trained and authorised persons who are familiar with the operating instructions and are able to work in accordance with it! • Before starting the machine, check and make sure that •...

  • Page 11: Work On The Electrical Equipment

    Operators Manual ALS 230 1.2.7 Work on the electrical equipment Repair work on the electrical equipment of the machine may only be performed by a trained electrician! Electrical equipment must be checked on a regular basis! Loose connections must be fixed again!

  • Page 13: Description

    Operators Manual ALS 230 2. Description CAUTION! - The machine is connected to mains. Only authorised personnel may open the cover. Operation without this cover is not allowed. This chapter explains the structure and the function of the labeller. The expressions used are explained here.
  • Page 14 Operators Manual ALS 230 Figure 1 Dispensing mechanics At the dispensing edge (010) the label is separated from the backing paper. By means of a soft (005) roller the label is applied on to the product. Roller (012) makes sure that the material is always guided properly around the dispensing edge.

  • Page 15: Operator Panel

    Operators Manual ALS 230 Dispensing is only possible when the handle (015) is in the closed position. Via the deviator roller (016) the backing paper is guided to the rewind mandrel (017). The cone between the 4 pins can be pulled out to allow the reward backing paper to be removed.
  • Page 16 Operators Manual ALS 230 PRIOR: This key moves up the menu (prior function) or increases the value of a parameter. If the up arrow key is pressed and held as the machine is turned on the product menu is selected.

  • Page 17: Plug Board

    Operators Manual ALS 230 2.3 Plug board The plug board is shown in Figure 3. Beside the mains switch and the mains cable socket there are some more holes for optional functions. Standard execution in this machine is one I/O plug prepared for the product sensor.
  • Page 18 Operators Manual ALS 230 Release 11/05 Page 16 Description...

  • Page 19: Preparing The Machine

    Operators Manual ALS 230 3. Preparing the machine In this chapter you will learn how to install and adjust the labeller. After this step has been completed you will be ready to learn how the labeller's parameters can be adjusted to suit your particular production requirements.

  • Page 20: Prepare Dispensing

    Operators Manual ALS 230 1.2 Prepare dispensing 1.2.1 Insert material Insert your label material in the machine to follow the instructions in the chapter Operation / Threading. 1.2.2 Define label data For correct dispenser operation, you have to tell the machine the length of the label and adjust the label sensor.

  • Page 21: Capacitive Label Sensor

    Operators Manual ALS 230 Setting LPIT manually To initialise labels with cut outs such as the one shown below - the "LPIT" parameter should be used to enter the label pitch of the label web. Figure 4 Definition of LPIT All other label edges seen by the label sensor will be ignored until the distance adjusted in the "LPIT"...

  • Page 22: Label Guide

    Operators Manual ALS 230 A mechanical sensor is limited in the speed. The bounce at the label edges produces wrong signals. There is optional a capacitive label sensor available (Leuze GK14/24L). Adjustment of the sensor is carried out as follows (Figure 5): 1.

  • Page 23: Adjust Dispense Function

    Operators Manual ALS 230 With a L-dispensing the adjustment is done by move the tail sheaves behind the dispensing edge. 3.3 Adjust dispense function For an operation without any trouble and high label accuracy, tree adjustments are required: • Label position on the dispensing edge: stop position •...

  • Page 24: Automatic Dispensing Speed (Apsf)

    Operators Manual ALS 230 3.3.3 Automatic dispensing speed (APSF) With a connected rotary encoder, the dispensing speed follows the measured product speed. To adjust the speed use the EGRA function located in the extended standard menu. The measured speed will be displayed in the VELO function. Do the adjustment in the same way described for fixed speed.

  • Page 25: Operation

    Operators Manual ALS 230 4. Operation This chapter describes the operation of the machine. 4.1 Safety recommendation CAUTION! Before connections to the mains check the correct voltage selection. Use only original spare parts for service. Open of the cover is only allowed authorised personal.

  • Page 26: Inserting Label Material

    Operators Manual ALS 230 4.2 Inserting label material Attention: • Before threading the new material, the waste paper should be removed. CAUTION! - Isertion/exchange of material should be carried out only by especially instructed personal. Threading of the label material is shown down below on the threading diagrams for the right-hand and the left-hand version.

  • Page 27: Initialise New Label Material

    Operators Manual ALS 230 4.3 Initialise new label material The machine requires data of the label material in use i.e. label length and opacity of the label and backing material. In most cases, those parameters can be scanned during automatic initialisation.

  • Page 28: Control Of Dispense Unit

    Operators Manual ALS 230 4.4 Control of dispense unit 4.4.1 Dispenser Menu selection Turning on the mains switch and at the same time pressing one of the panel keys, you may select between several options: PANEL KEY & mains switch...
  • Page 29 Operators Manual ALS 230 Error display: If the display shows e.g. E__XX, the dispenser has recognised an error. A warning is shown by W_XX. As soon as the error has been corrected, you may erase the message by pressing the key ENTER and you will get back to the status the machine was in before the error was indicated.
  • Page 30 Operators Manual ALS 230 pressing the key PRIOR the value is increased, i.e. the label is put on later. By pressing the key NEXT FUNCTION the value is decreased and the label is put on earlier. The labelling position is also changed by variation of the product speed. In this case first control you product speed and the dispense speed VELO.
  • Page 31 Operators Manual ALS 230 Figure 9 Stop position Dispense speed __________________________________________________VELO The speed value VELO displays the dispensing speed in 0.1 m/min. The product conveyor speed has to be constant to assure accurate labelling. A change of the product speed causes a different position of the label on the product.

  • Page 32: Maintenance

    Operators Manual ALS 230 If you want to switch to another product, select the respective product number by pressing NEXT and PRIOR, then press ENTER. Now the new product data are activated. To change the labelling parameters you can call the extended menu. After leaving this menu, your product data will be automatically updated.

  • Page 33: Menu Structure

    Operators Manual ALS 230 5. Menu structure The touch panel keys or the optional interface can change labeller parameters. The last entered parameters are the actual ones the machine works with. Programming via the interface is described in chapter Serial interface.
  • Page 34 Operators Manual ALS 230 • at power on Standard menu Extended menu INIT/ON/OFF Direct INIT/ON/OFF STOD VELO Applicator INIT/ON/OFF STAD BLOW Direct dispense Release 11/05 Power On at power on CODE Product menu INIT/ON/OFF LPIT PD01 CONT PD02 SENS PD03...

  • Page 35: Standard Menu

    Operators Manual ALS 230 5.1 Standard menu Usually this menu is used for labelling. All important parameters can be changed while the machine is running. After turning power on, the standard menu is active, unless the product menu was on before the machine was switched off.
  • Page 36 Operators Manual ALS 230 Label position ____________________________________________________POS Function: The start position POS defines when the labelling should take place, after the product has passed the product sensor. Changing the value for POS changes the applied label position on the product.

  • Page 37: Extended Standard Menu

    Operators Manual ALS 230 5.2 Extended standard menu The extended standard menu offers additional parameters you may use in your application. On quitting this menu the current parameter settings are stored in memory. Further changes are also written into memory. As long as this menu is active, no labelling is possible. By pressing the key FEED, however, single dispense of labels is possible.
  • Page 38 Operators Manual ALS 230 Display Function Printer dwell time Printer hold time (is 50% PDT) SAVE Store data in the product data bank LOAD Load data from a product data bank QUIT Leave the extended standard menu Label pitch _______________________________________________________LPIT Distance between 2 labels on the label web, measured from leading edge to leading edge.
  • Page 39 Operators Manual ALS 230 Stop position ___________________________________________________ STOD Function: Stop position of the label at the dispensing edge. Available: Always Range: 0.0 ... 200.0 mm Product length ___________________________________________________PRDL Function: The product length avoids multi labelling in case of difficult products. Normally it is set to AUTO.
  • Page 40 Operators Manual ALS 230 Start delay ______________________________________________________STAD Function: Delay time for the dispensing by means of an applicator after the product has passed the product sensor. This value influences the position of the label on the product. Only available if applicator is used.
  • Page 41 Operators Manual ALS 230 Blow on time_____________________________________________________ APT2 Function: Only used when an applicator is necessary. It defines for how long the label is blown onto the product. Available only with applicator. Range: 1 ... 7500 ms Restart delay ____________________________________________________ APT3 Function: This parameter defines the time for a next label dispense after the applicator cycling is completed.
  • Page 42 Operators Manual ALS 230 End of air stream signal ___________________________________________ ASTP This parameter determines how long the air stream signal will remain active after the label dispense has finished. Valid in all modes (direct dispense, applicator, APSF and fixed-speed). Printer dwell time__________________________________________________ PDT This determines the dwell time of the stamp-printer.

  • Page 43: Product Menu

    Operators Manual ALS 230 5.3 Product menu If parameters have to be changed because of different products and labels, the product menu can be used. The machine offers a data bank in which 14 sets of data can be stored.
  • Page 44 Operators Manual ALS 230 Release 11/05 Page 42 Menu structure...

  • Page 45: Configuration

    Operators Manual ALS 230 6. Configuration Adjustments in the configuration menu are necessary during installation of the machine only. In the configuration menu, the required optional functions can be selected. Some service support functions in the configuration menu will be useful for the service staff.

  • Page 46: Handling The Menu

    Operators Manual ALS 230 6.1 Handling the menu The menu structure is shown in the following table. By means of the key PRIOR you switch to the prior function, and with the key NEXT to the next following function in the menu.

  • Page 47: Menu Functions

    Operators Manual ALS 230 6.2 Menu functions The menu functions are explained in detail here. Permanent test ___________________________________________________ DTST The permanent test makes a test run without using labels. In the display the numbers of dispense cycles is shown (see description LABC). Immediately after starting the function, the machine runs in a self-test.
  • Page 48 Operators Manual ALS 230 With this function, you can decide how to react: NONE Do nothing. The unlabeled product will be detected later in the line. WARN Set the warning output and displays W__0. The production continued. ERR1 Set the error output to stop the production line immediately and display E_10.
  • Page 49 Operators Manual ALS 230 Additional functions in the standard menu Depending on which parameter has been defined under APPL different menu functions are shown in the standard menu. If an applicator is used additional times BLOW and STAD for controlling the applicator cycling are available.
  • Page 50 Operators Manual ALS 230 6 = terminal 20 = ERROR 7 = terminal 31 = READY 8 = terminal 32 = ODC_OUT / HORI_CYL Adjustment resetting______________________________________________ FACT This menu point sets all parameters back to the factory values. All parameters will be reset, so please note all your adjustments before.
  • Page 51 Operators Manual ALS 230 Number of data bits _______________________________________________ DBIT The function is only visible if a baudrate is selected. With this function you can select between 7 or 8 data bit protocols. Factory adjustment: 8BIT Recycle (simulates max labels/min) ________________________________ RECY The Auto-recycle function, is used to determine the maximum possible cycle rate with the current parameter settings.
  • Page 52 Operators Manual ALS 230 Note: Modified parameter values are only stored if the menu is left by using the QUIT function. If the power is switched off before leaving the menu by quit all modifications are lost. Release 11/05 Page 50...

  • Page 53: Serial Interface

    Operators Manual ALS 230 7. Serial interface The machine has a serial interface according to the standard RS232C. Via this interface parameters can be adjusted. All received commands are tested for syntax and legal value range. Invalid commands and parameters are ignored. An error message is not given in this case.

  • Page 54: Interface Commands

    Operators Manual ALS 230 7.2 Interface commands The below described commands will change one of the labelling parameter. The values are not stored and will be lost when turning off power. If the sequence nnnn is replaced by the character "?" then the current value of that parameter will be returned by the labelling machine as a 4 character string confirming the name of the parameter requested followed by 4 numbers representing the current value of that parameter.
  • Page 55 Operators Manual ALS 230 Command Description #!MDIRnnnn Motor direction #!MLABnnnn Missing label error #!PDT nnnn Print dwell time #!PHT nnnn Printer hold time #!POS_nnn Labelling position #!PRDLnnnn Product length #!P_S_nnnn Polarity product sensor #!RAMPnnnn Acceleration Ramp #!SLEWnnnn Slew speed #!STADnnnn...

  • Page 56: Bit Definition In Error Flag

    Operators Manual ALS 230 #!SR__ The machine is set to on. The product sensor is enabled and labelling can restart. For a full automatic operation, the following procedure in case of an error is required: • #!ERRF Request error •...

  • Page 57: Connections And Signals

    Operators Manual ALS 230 8. Connections and signals This machine has a number of inputs to connect sensor’s and a control. Outputs are available for applicators, a printer and other purposes. 8.1 Output signals This machine has eight outputs, which switch the output from open circuit to + 24V. The maximum current must not exceed 500 mA.

  • Page 58: Applicator Modes

    Operators Manual ALS 230 8.2 Applicator modes The machine is able to dispense the label direct on the passing product. There is also the possibility to drive without any external control a wide range of applicators. 8.2.1 Signals for direct dispense For direct dispensing the airstream signal can be used to control a pneumatic driven dispensing edge.

  • Page 59: Control Signals For The Asa Applicator

    Operators Manual ALS 230 8.2.2 Control signals for the ASA applicator For controlling an air stream applicator the signals air- stream and blow on are necessary. The time period APT2 defines how long the blow on signal is active. After labelling the product and the time period of APT3 a new label will be dispensed on to the applicator.

  • Page 60: Signals For The Ep Applicator

    Operators Manual ALS 230 8.2.3 Signals for the EP applicator For controlling the applicator the signals air stream, cylinder valve and blow on are necessary. After a product signal has occurred the labelling cylinder valve is switched active after the delay STAD.

  • Page 61: Applicator Connector

    Operators Manual ALS 230 8.2.4 Applicator connector The applicator connection is done via a 15 pole D-sub connector common to other machines. Figure 13 Applicator connector Release 11/05 Page 59 Connections and signals...

  • Page 62: Input Signals

    Operators Manual ALS 230 8.3 Input signals This machine (dispenser) is provided with photo coupled inputs for: the product sensor signal an inhibit signal for inhibiting labelling a signal from an OD control which shows the end of the material roll.

  • Page 63: Product Sensor

    Operators Manual ALS 230 8.3.1 Product sensor The product sensor starts the labelling. The source of the signal could be a optical sensor, a switch or a signal from a PLC. The time between start signal and start of dispensing (adjusted with POS) should be as small as possible.

  • Page 64: Od Control Sensor

    Operators Manual ALS 230 8.3.2 OD Control sensor Optional an OD control could be mounted to control the label roll. If the label material is nearly empty the sensor gives an signal. A warning message and an output signal inform the personal that in the next time the material has to be changed.

  • Page 65: Apsf Sensor

    Operators Manual ALS 230 8.3.3 APSF sensor For the APSF function (Automatic speed follower) a rotary encoder has to be installed. For optimum labelling accuracy the rotary encoder should be selected so that it produces one pulse for every 0.125 mm of product movement. The connection of the encoder should be done with a shielded cable.

  • Page 66: Control Signals

    Operators Manual ALS 230 8.3.4 Control signals An optional connector could be installed for integration of the machine in the line control. Inhibit + Startunterdrückung + +24 Volt +24 Volt Inhibit - Startunterdrückung - Error output Fehlerausgang Warning output Warnausgang...
  • Page 67 Operators Manual ALS 230 Figure 22 Internal I/O connector Release 11/05 Page 65 Connections and signals...

  • Page 68: Emi

    Operators Manual ALS 230 8.4 EMI To protect the machines against electrical noise and to protect production of electrical noise you have to follow this rules: Rule 1 All metallic parts must have a good and plane contact (no lacquer, aluminium oxide is an isolator).

  • Page 69: Electronic Diagrams

    Operators Manual ALS 230 8.5 Electronic diagrams Figure 23 Wiring diagram Release 11/05 Page 67 Connections and signals...
  • Page 70 Operators Manual ALS 230 Figure 24 Layout dispenser electronic board Release 11/05 Page 68 Connections and signals...
  • Page 71 Operators Manual ALS 230 48VAC 48VAC Phase1A Phase1B + Direction - Direction - Clock + NC - NC Ready Collector Ready Emitter Figure 25 Layout stepper motor driver The jumper position has to be 800 steps. Figure 26 Display jumper setting...

  • Page 73: Errors And Warnings

    Operators Manual ALS 230 9. Errors and warnings The software checks during the labelling permanently, if the machine runs under normal operation. If labelling is not possible, the display shows a message e.g. E__0. If the labelling can be continued, but a problem has occurred or may occur, the display shows a warning e.g.
  • Page 74 Operators Manual ALS 230 Message Meaning to the factory adjustment. E__4 Check sum of the labelling data is wrong. Labelling Parameters are set to the factory adjustment. E__5 10V supply voltage for label sensor low. E__6 24V Voltage low E__7...

  • Page 75: Dispenser Warnings

    Operators Manual ALS 230 9.2 Dispenser warnings In case of a warning message the relevant output is switched. The signal can be used for interconnection with an external machine control. Warning W__5 activates only the special OD warn output. Message...
  • Page 76 Operators Manual ALS 230 Release 11/05 Page 74 Errors and warnings...

  • Page 77: Technical Specification

    Operators Manual ALS 230 10. Technical Specification The following data are maximum values. Depending on label material, operation environment and labelling condition the real value could be lower. 10.1 Technical Information Description Label width: incl. Backing paper Label length Diameter label roll...

  • Page 78: Application Specification

    Operators Manual ALS 230 Description Power consumption Mains voltage 10.2 Application specification The labeller is designed and built for automatic applies of self-adhesive labels. 10.3 APSF- Sensor Specification (Optional function) The resolution of the sensor should be selectedsuch per 1mm product movement 1 to 5 pulses are generated.

  • Page 79: Performance

    Operators Manual ALS 230 10.4 Performance The following tables show the maximal theoretically labels per minute rate. Tolerances in product speed, label and product dimensions reduce the label rate. The tables are valid for direct dispensing (without applicator and printer). For critical applications, performance test should be done first.

  • Page 80: Dispensing Speed Reached While Dispensing Certain Label Length

    Operators Manual ALS 230 10.4.2 Dispensing speed reached while dispensing certain label length Dispensing speed reached in reference to label length dispensed Label length Dispensing (mm) speed reached at certain label length (m/min) 0,375 0,75 1,125 1,875 2,25 2,625 3,375...
  • Page 81 Operators Manual ALS 230 Note: As in most real labelling environments the products will have a spacing of at least 1cm the actual labelling rate can simply be calculated by dividing the product pitch into the conveyor speed. Product length = 100 mm; Product distance = 50 mm;...

  • Page 83: Adjustment

    Operators Manual ALS 230 11. Adjustment Function Factory P_S_ LEDG MACH MDIR RAMP FAST MLAB WARN COMP APSF APPL BAUD NONE PARI SBIT 2BIT DBIT 8BIT DIST 76.0 mm SLEW FAST Release 11/2005 Application Page 81 11 Adjustment...
  • Page 84 Operators Manual ALS 230 Function Factory POS(STAD) 100.0 mm VELO 30.0 m/min STOD 76.0 mm BLOW(APT2) 1 ms LPIT AUTO CONT AUTO PRDL AUTO EGRA APT1 200 ms APT3 0 ms APOS ASTP Function PD05 POS(STAD) VELO STOD BLOW(APT2) LPIT...

  • Page 85: Index

    12. Index applicator ... 53, 55 Applicator... 42 APSF ... 40, 42, 58 ASA... 53 Automatic product speed follower... Siehe APSF capacitve label ... 16 configuration menu ... 39 Configuration menu ... 27 Direction... 41 DIST... 45 DTST ...Siehe Permanent test EP applicator ...

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