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Novexx Solutions ALS 30 Series Installation Manual

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INSTALLATION MANUAL
ALS 30x
Labeler
Edition 2 - 1/2016 - Translation of original version

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Summary of Contents for Novexx Solutions ALS 30 Series

  • Page 1 INSTALLATION MANUAL ALS 30x Labeler Edition 2 - 1/2016 - Translation of original version...
  • Page 3 ALS 30x Installation Manual Contents Please observe the following General information Validity and applicability of this manual Conventions and information Notes on installation and repair work Safety instructions Information and qualifications Machine operating safety Safe operation Technical Data Dimension diagrams Installation and Deinstallation Admissible operation positions Top labelling...
  • Page 4 ALS 30x Installation Manual 02/2016 Contents...

  • Page 5: Please Observe The Following

    10. Copyright notice All rights to this operating manual are assigned to NOVEXX Solutions. Transmission, reprinting or any other means of reproduction of this manual, whether whole or in part, are not allowed without prior written permission. Third parties, in particular competitors, are not to be allowed access to information derived from this manual.
  • Page 6 ALS 30x Installation Manual Conventions and information Explanation of symbols In order to facilitate legibility and an overview, the various types of information used herein are cat- egorised and identified with certain symbols. Sentences that are introduced by an arrow contain procedural instructions. ...
  • Page 7 ALS 30x Installation Manual Tightening torques: – Tightening torques for the listed screw connections If special tools or other aids are needed for a task: Tools: – List of the tools and aids that are required for the following activities Notes on installation and repair work General information Before performing any maintenance or repair work:...
  • Page 8 ALS 30x Installation Manual Rules for electromagnetic compatibility Connect all metallic parts to each other via large surfaces, ensuring electric conductivity. – Only polished metal surfaces are electrically conductive. Painted or oxidised surfaces are unsui- table. Aluminium which appears to be polished still has an invisible oxidation layer on the surfa- –...

  • Page 9: Power Filter

    ALS 30x Installation Manual Power filter Mount the power filter direct at the power supply.   Connect the filter casing to the EMC grounding via large metal surfaces. Lay all lines as close as possible to metal parts, even reserve cables –...

  • Page 10: Safety Instructions

    ALS 30x Installation Manual SAFETY INSTRUCTIONS Information and qualifications Ensure necessary qualifications  Only allow appropriately qualified personnel to set up, adjust, and repair the labeler, e.g. me- chanical and electronics specialists.  Only allow work on the electronics system to be done by authorised electronics technicians. Clearly define the responsibilities for installing, setting up, adjusting, and repairing the labeler.

  • Page 11: Machine Operating Safety

     Only put the labeler into operation if it is in flawless condition.   Only perform alterations or conversions to the labeler with the consent of Novexx Solutions's customer service.  Only use original replacement parts. Danger of body part trapping and pinching at the dispensing edge due to products moving in the conveyor direction! ...

  • Page 12: Safe Operation

    ALS 30x Installation Manual Protection measures in applicator mode WARNING! Danger of crushing between dispenser edge and applicator pressure plate due to applicator mo- vement!  Prevent personnel from reaching between dispensing edge and applicator by installing hig- her-level protective equipment 1) Movable, separating guards according to EN 953 After all servicing or repair work WARNING!
  • Page 13 ALS 30x Installation Manual (ALS 104 with splash guard) The power cable cannot be pulled off from the machine side power connector .  If the machine is connected to a cabinet, a suitable and accessible power separator must be provided by the system integrator.

  • Page 14: Technical Data

    ALS 30x Installation Manual Technical Data DIMENSION DIAGRAMS ALS 306: 477 ALS 309: 539 22,6 71,25 [2] Dimensions ALS 30x - Part 1 02/2016 | 00 Technical Data...
  • Page 15 ALS 30x Installation Manual [3] Dimensions ALS 30x - Part 2 02/2016 | 00 Technical Data...

  • Page 16: Installation And Deinstallation

    ALS 30x Installation Manual Installation and Deinstallation ADMISSIBLE OPERATION POSITIONS Key for the mounting points marked in the illustrations:  Recommended  O.k.  Not recommended Mounting point on the rear side Top labelling The pictures [4] to [9] show the possible operational positions of an ALS 30x with two unwinders for top labelling.

  • Page 17: Vertical Position

    ALS 30x Installation Manual Vertical position [7] Vertical mounting position for top labelling. [9] Vertical mounting position for top labelling. [8] Vertical mounting position for top labelling. 02/2016 | 00 Installation and Deinstallation...
  • Page 18 ALS 30x Installation Manual Side labelling The pictures [10] to [15] show the possible operational positions of an ALS 30x with two unwinders for side labelling. The arrows indicate the recommended lateral fixing points. An additional fixing point is positioned at the rear side.
  • Page 19 ALS 30x Installation Manual Vertical position [15] Vertical mounting position for side labelling. [13] Vertical mounting position for side labelling. [14] Vertical mounting position for side labelling. 02/2016 | 00 Installation and Deinstallation...
  • Page 20 ALS 30x Installation Manual UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE Transport CAUTION! To avoid damaging the machine during transport:  Only transport the machine in its origi- nal packaging.  Keep the original packaging for a later transport. Unpacking WARNING! Acute risk of injury and long-term bodily injury from working with heavy loads! ...
  • Page 21 ALS 30x Installation Manual Setting up WARNING! Risk of injury from a tipping over support stand.  When installing the machine on a sup- port stand, make sure that it can not tip over.  Fix the support stand onto the ground. Prerequisites: Support stand with a tube end providing the following measures:...
  • Page 22 ALS 30x Installation Manual Holding machines in place with the adjustable head joint By means of the adjustable head joint, the labeller can be easily inclined by an angle of ±4° by a single opera- tor. max. 4° [19] Adjustable head joint, assembled max.
  • Page 23 ALS 30x Installation Manual Assembly Turn the adjustment screw [25A] and both clamp  screws [25C] some rotations out. [25] Machine side bracket ready mounted.  Insert the support stand side bracket [26A] and push in the axle [25B] flush. [26] Assembling the support stand side bracket (A).
  • Page 24 ALS 30x Installation Manual Holding machines in place with the flange plate – Order number for flange plate assembly [29C] (in- cluding screws and washers): A7622 Tool: – 8/10 mm hexagon socket driver  Screw the flange plate [29C] to the appropriate flan- ge at the machine.
  • Page 25 ALS 30x Installation Manual Mounting the unwinder Tool: – 8 mm hex socket driver Prerequisites: – RH unwinder: The mounting positions top right and side right require a RH unwinder, see rating plate [32arrow]. – LH unwinder: The mounting positions top left and side left require a LH unwinder, see rating plate [32arrow].
  • Page 26 ALS 30x Installation Manual Mounting the unwinder to the holder The unwinder holder provides a stud [33A]on each side of its flange. The stud on the dancer arm side must engange with one of the 5 holes in the lever plate [33C] on the dancer arm.
  • Page 27 ALS 30x Installation Manual Mounting the dispensing edge holder Tools: – 2.5/5 mm hex socket screwdriver – 8 mm hex socket key, 20 cm long – Piece of tube as lever About dispensing edge holders The following dispensing edge holders are available for ALS 30x: –...
  • Page 28 ALS 30x Installation Manual Installing short dispensing edge holder For mounting angle > 0°, an additional deflection roller has to be mounted: Article number deflection roller: – A9724 for ALS 306 – A9808 for ALS 309 Swivel the dispensing edge holder to the required ...
  • Page 29 ALS 30x Installation Manual Installing long dispensing edge holder vertically  Screw the dispensing edge holder to the 2 mounting points [42A]. – The 2 screws can be reached through the hole in the 2 cross beams.  Close the holes using the plastic caps. [42] Mounting points (A) for vertical mounting 02/2016 | 00 Installation and Deinstallation...
  • Page 30 ALS 30x Installation Manual Installing long dispensing edge holder horizontally Horizontal mounting (90°) of the dispensing edge hol- der requires 2 additional deflection rollers. Article numbers roll kits: – A9766 for ALS 306 – A9810 for ALS 309 RH machines: Before assembling the dispensing edge holder, two modifications are necessary: –...
  • Page 31 ALS 30x Installation Manual RH/LH machines: Screw the dispensing edge holder to the 2 mounting  points [45A]. – The 2 screws can be reached through the hole in the 2 cross beams.  Close the holes using the plastic caps. [45] Mounting points (A) for horizontal mounting Mounting the Euro dispensing edge holder The Euro dispensing edge holder is mounted in the...
  • Page 32 ALS 30x Installation Manual Setting length of the short/long dispensing edge holder The length adjustment range depends on the type of dispensing edge holder and on the mounting angle. In some cases, it may be advisable to shorten the holding rods at their top ends.

  • Page 33: Connecting To The Mains Power Supply

    ALS 30x Installation Manual Connecting to the mains power supply WARNING! The machine is connected with the mains supply! Contact with energised components can result in life-endangering currents through the body as well as burns.  The mains connection may only be performed by authorised specialists who are aware of the risks involved.
  • Page 34 ALS 30x Installation Manual Tools: – Screwdriver size 2 Connecting:  Select a 3-wire power cable with a cross section matching the mains voltage/current in your country. Strip the insulation off the power cable according to  the regulations.  Thread the cable end through the connector housing [51].
  • Page 35 ALS 30x Installation Manual Connecting / mounting the external operator panel Connecting to a standard machine The external operator panel is necessary, if the labeller is installed at an inaccessible place. The cable installed to the operator panel is 2.5 m long. CAUTION! If the connection cable is longer than 2.5 m, EMC-caused disturbances can...
  • Page 36 ALS 30x Installation Manual  Feed the operator panel cable [55C] through sealing [55F], cover plate and nut [55G].  Push the seal ring [55F] over the thread. Insert the cable gland into the opening in the cover  box and fix it with the nut [55G] from inside. ...
  • Page 37 ALS 30x Installation Manual Mounting the bonding unit [57] Assembling the bonding unit for RH machines. [60] ALS with bonding unit (A). The bonding unit [60A] is an accessory for ALS 30x labellers, which are operated with two lateral unwin- ders.

  • Page 38: Connecting The Sensors

    ALS 30x Installation Manual CONNECTING THE SENSORS Photoelectric label sensor – Permitted sensor type: NPN – Photoelectric label sensor is included in the dis- pensing edge scope of delivery [61] Article numbers: – A101974: Sensor with bracket and cable (1.5 m) –...

  • Page 39: Connection Diagram

    ALS 30x Installation Manual Connection diagram +24V +24V Label gap detection signal Label signal input LED current Current feed output back signal 0..20mA LED current setting Label sensor [64] Connection diagram for photoelectric label sensor The LED current at pin 2 controls the sensitivity of the sensor.
  • Page 40 ALS 30x Installation Manual Adjusting the Novexx sensor  Press the button [65A] for 2 s, until the status LEDs [65B] light permanently. – Notice: Don´t press the button for longer than 5 s, otherwise you risk to switch between NPN/PNP, see chapter Switching the Novexx sensor - PNP/NPN ...
  • Page 41 ALS 30x Installation Manual Switching the Novexx sensor - PNP/NPN Default setting: NPN Switching between NPN/PNP:  Press the button [68A] for at least 6 s, until the status LEDs [68B] flash 2x. Finding out the current setting: Move some label material through the sensor fork ...
  • Page 42 ALS 30x Installation Manual Adjusting the Wenglor photoelectric sensor automatically Only for Wenglor sensors (old standard, replaced since 9/2011 by Novexx sensor). MACHINE SETUP > Auto Sensor Adj.  Call up – The label material is fed slowly until the next gap between labels (punch) is reached.
  • Page 43 ALS 30x Installation Manual Alternative label sensor Other suitable sensors can be used as an alternative to the throughbeam photoelectric sensor. – Permitted sensor types: PNP or NPN – Default setting: PNP Alternative label sensor and standard photo- electric sensor may both be connected at the same time.
  • Page 44 ALS 30x Installation Manual Connection Diagram +24V +24V NPN-Configuration 2,2k NPN-Signal 1,5k Signal Input Sensor connector PNP-Signal 2,2k PNP-Configuration Jumper (default: open) [71] Connection diagram alternativ label sensor. Jumper descripti- on see ch. (p. 46) Example: capacitive label sensor – Application: transparent Labels –...
  • Page 45 ALS 30x Installation Manual Positioning the sensor holder: The sensor holder be varied in a wide range on the hol- ding rods. The most favorable position can be found as follows: – Label web is in stop position (position just after dispensing a label).
  • Page 46 ALS 30x Installation Manual Changing light/dark switching at the product sensor or the alternativ label sensor Basically, sensors can be assigned to three dif- ferent groups regarding the function of pin 2: a) Pin 2 has no function b) Pin 2 = input, e.g. for light/dark switching c) Pin 2 = output, e.g.
  • Page 47 ALS 30x Installation Manual Photoelectric product sensor – Permitted sensor types: PNP or NPN – Preset: PNP – Order no.: A7112 [77] Connecting the photoelectric sensor  Plug the product sensor in to the connector shown [78A]. For NPN Photoelectric sensor: MACHINE SETUP >...
  • Page 48 ALS 30x Installation Manual External roll diameter sensor [82] External OD sensor. The ALS30x can be equipped with an optional sensor [82] to check the outer diameter (OD sensor) of the label roll. The OD sensor triggers a display mes- sage and a signal at the signal interface, if less than a certain residual diameter is left on the label roll.
  • Page 49 ALS 30x Installation Manual Connecting  Plug the roll diameter sensor in to the connector shown [83 arrow]. Alternatively, the OD sensor can be connected to the optional applicator interface (see chapter “Pin assign- ment for applicator connection” on page 180). Enabling MACHINE SETUP >...
  • Page 50 ALS 30x Installation Manual Pin assignment Assignment +24 V not used Ground Sensor signal [Tab. 5] Pin assignment for OD sensor connection Setting the roll diameter Prerequisite: – OD sensor is installed an activated. – Label material roll with the required remaining diam- eter is prepared.
  • Page 51 ALS 30x Installation Manual Function test Prerequisite: – Machine is in dispensing mode. MACHINE SETUP > OD sensor warn. – = „Warning“ (set- tings according to“Enabling” auf Seite 49). If the light beam of the sensor [85C] meets the reflector, the following warning appears after the next label has been dispensed: ONLINE...
  • Page 52 ALS 30x Installation Manual Internal OD-sensors The internal OD-sensors are integrated in the material unwinder. Precondition for activating the sensors is, that they are connected to the ALS 30x. Two unwinders can be connected overall. Each unwinder requires a cable kit. Prerequisite: –...

  • Page 53: Function Test

    ALS 30x Installation Manual Function test Critical OD reached: – If the set diameter is reached, the following warning appears: ONLINE Material low – Additionally, the following signals will be activated: Interface Signal name Standard signal interface Warning Applicator interface OD-Sensor (optional) Material roll motionless (what means completely...

  • Page 54: Rotary Encoder

    – Type: 9109.10 – Order no.: 045565 Suitable mounting [90B]: – Type: 9213 – Order no.: 045492 Novexx Solutions article number for the above [90] Recommended rotary encoder from Pepperl + Fuchs mentioned encoder including measuring wheel A Measuring wheel B Mounting and mounting: A7770.
  • Page 55 ALS 30x Installation Manual Connecting the rotary encoder CAUTION! To avoid damage to the electronics:  Switch the machine off before con- necting the rotary encoder.  Plug the rotary encoder in to the connector shown [91A]. No changeover is necessary for a Push-Pull rotary encoder.

  • Page 56: Take The Machine Out Of Operation

    ALS 30x Installation Manual DECOMMISSIONING, DISMANTLING, DISPOSAL Take the machine out of operation Disconnecting the machine from the compressed air supply (only machines with installed applica- tor):  Switch off the compressed air supply of the applicator.  Disconnect the compressed air hose from the applicator. –...

  • Page 57: Machine Disposal

    ALS 30x Installation Manual Machine disposal It is advisable to remove reusable machine components as long as the machine is firmly mounted.  Remove machine parts which can be reused (e. g. applicator, applicator interface, dispensing edge holder, dispensing edge). ...
  • Page 59 Novexx Solutions GmbH Ohmstraße 3 85386 Eching Germany  +49-8165-925-0 www.novexx.com...

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