Page 1 User's Manual Manual for Installation, Setup and Operation ALPHA V40 Part Number of Document: 21800863 Copyright © 2006, Geset Etikettier-Systeme GmbH L.Krämer Version: 18.07.06 Geset Etikettier-Systeme GmbH Jakobstraße 79 D-73734 Esslingen E-Mail: info@geset.com 21800863 http://www.geset.com...
Page 2 NOTE ! Geset Etikettier-Systeme GmbH insures that every effort has been made to ensure that the information in this manual is complete, accurate and up to date. Geset Etikettier-Systeme GmbH refuses any kind of warranty and assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual.
Page 3: Table Of Contents
Glossary ALPHA V40 Contents list 1. Introduction ........................9 Purpose and Scope of this Manual ..................9 Conventions Used in this Manual...................10 Manual Outline ........................12 Service – Hotline ........................13 2. General Information ......................14 Compressed Air and Power ......................14 Specifications .........................14 Installation ..........................15 Important indication for the installation / putting into operation............
Page 4 Glossary ALPHA V40 Applicator Setup........................44 Air Assist Setup ........................44 Blow-Box Setup........................46 Vacuum Adjustment .......................... 46 Vacuum Box Grid Setup........................47 Air blast Tube Arrangements ......................48 Tamp-Blow Setup........................49 Vacuum Setup........................... 49 Piston Speed Setting......................... 50 Home Sensor Adjustment ......................... 51 To Check Home Sensor Adjustment....................
Page 5 Glossary ALPHA V40 Address 05 (Page 0), sensor and peeling edge distance ..............79 Address 06 (Page 0), encoder reading ..................... 80 Address 07 (Page 0), diagnostic functions ..................81 Address 08 (Page 0), dispensing speed (of label format #1)............82 Address 09 (Page 0), label positioning (of label format #1) ..............
Page 6 Glossary ALPHA V40 Glossary Adhesive String: Label adhesive that adheres to the label and the label liner while the label is dispensing. It can cause the label to be improperly positioned on the tamp pad. Air Assist: The stream of air that the air assist tube directs at the label in order to help it come off of the label liner as it is dispensing.
Page 7 Glossary ALPHA V40 LED: Light Emitting Diode Label Feed: The process that feeds the label stock through the machine. Label Liner: The paper that the labels are affixed to before they are applied to the product. Label Sensor: The photoelectric sensor (pitch detector) that detects the presence of a label in the machine. Label Size: The length and width of the label.
Page 8 Glossary ALPHA V40 Static Stack: A stack of labels that have been applied one on top of the other. When the applicator is setup correctly, a static stack will have less than + or – 1/32 of an inch variation in any direction. Tamp: A mechanical device that receives a label and moves the label to a position where it is applied to a product.
Page 9: Introduction
Chapter 1 Introduction ALPHA V40 1. Introduction The ALPHA V40 incorporates a label applicator with controller unit. The Overview applicator is designed to accommodate a few different types of applicators (Wipe-On- or Tamp applicators and Blow Box). This chapter covers the purpose and scope of this manual, the conventions used to convey information and the manual outline.
Page 10: Conventions Used In This Manual
Chapter 1 Introduction ALPHA V40 Conventions Used in this Manual Following is a brief list of the conventions used in this manual: o A pointing hand symbol indicates special notes and warnings: NOTE: This is a special note. o Keys which you must press on the machine appear in a special boxed font: Press the [Enter] key to continue.
Page 11 Chapter 1 Introduction ALPHA V40 Pay special attention to any procedures that may have one of the following symbols. Read all of the Caution and Warning instructions and follow them when performing the corresponding procedures. CAUTION THIS SYMBOL IS USED TO WARN USERS OF DANGER FROM (POSSIBLE) ELECTRICAL SHOCK! READ ALL CAUTION STATEMENTS AND FOLLOW ALL THE INSTRUCTIONS TO AVOID A PERSONAL INJURY AND/OR EQUIPMENT DAMAGE...
Page 12: Manual Outline
Chapter 1 Introduction ALPHA V40 Manual Outline Chapter 1. Introduction Defines the purpose and scope of this manual. Explains the conventions used within the manual and lists an outline of the material covered. Includes customer support information. Chapter 2. General Information Includes specifications for proper air and power sources,...
Page 13: Service - Hotline
Chapter 1 Introduction ALPHA V40 Service – Hotline Please contact your system provider if any technical support is required: Distributor Label You should be prepared with the following information when being asked on the phone: Fault description gave full particulars All information on the name plate When did the error occur? - after loading labels.
Page 14: General Information
The air pressure must always be greater than the highest pressure setting on the machine. 3 SCFM is the typical air volume requirement. The rate of production and the label size can effect the air supply requirements. If you have problems in this area, check with Weber Customer Support.
Page 15: Installation
The complex job for a correct putting into operation and installation of Label Applicator must be coordinated in exactly sequences. This is prerequisite for a durable functional performance. Weber Marking Systems offers solutions for favourable, practice approved Systems Supports and Protection Cabinets. Benefit from our extensive experiences in all areas of industry.
Page 16: System Block Diagram
Chapter 2 General Information ALPHA V40 System Block Diagram See the ALPHA V40 Wipe-On versions as a left hand and a right hand system as follows: Figure 2-1: ALPHA V40 in left hand version (LH) FIG. 2-1: ALPHA V40 (LH) Version 18.07.06...
Page 17 Chapter 2 General Information ALPHA V40 Figure 2-1: ALPHA V40 in right hand version (RH) Fig. 2-2: ALPHA V 40 (RH) Version 18.07.06...
Page 18: Applications Modes
Chapter 2 General Information ALPHA V40 Applications Modes The ALPHA V40 applies labels onto a moving or stopped product. Depending on applicator version there are different application modes. They can be selected via display controller. Wipe-On-Mode (Standard) In the Wipe-On version the labels are peeled off from the carrier, and applied to the product by precise stepping motor.
Page 19: Preliminary Setup
Chapter 3 Preliminary Setup ALPHA V40 3. Preliminary Setup The preliminary setup includes all the procedures that can be done before the Overview AC power is connected to the machine. The machine enclosure must be removed before working on some of these procedures. Use caution when removing the enclosure.
Page 20 Chapter 3 Preliminary Setup ALPHA V40 3. Place the applicator with its backside on an adequately stable work surface that is approximately high of your stand. 4. After proper assembly of the stand (per assembly instructions), adjust the height of the carriage if available until the machine.
Page 21: Possible Machine Attitudes
Chapter 3 Preliminary Setup ALPHA V40 Possible Machine Attitudes Fig.3-2: Definition of Machine Attitudes Version 18.07.06...
Page 22 Chapter 3 Preliminary Setup ALPHA V40 6. Transportation of applicator Systems mounted to stands without castors, have to taken apart to be transported. A T-base with castors is only designed to provide roll-away access from the adjacent labeling area for applicator service. If the applicator needs to be transported over a greater distance, several additional safety measures must be followed when using a T-base stand.
Page 23: Label Loading
Chapter 3 Preliminary Setup ALPHA V40 Label Loading 1. Open the clamp device of the outer unwind disk and remove the outer unwind disk from the unwind mandrel. 2. Load the label roll onto the label-roll-support (located in between the unwind discs) and up against the inner unwind disk.
Page 24 Chapter 3 Preliminary Setup ALPHA V40 10. Peel off the first 600 mm of labels (beginning at peeling blade position) from the label liner. Slide the backing paper to the drive roller. 11. The friction roll can be lifted using its rounded pin for an easier threading. 12.
Page 25: Change For Label Roll
Chapter 3 Preliminary Setup ALPHA V40 Change for Label Roll Switch off the machine before you perform the following. - Pull up the u-pin from the rewind mandrel and remove the whole backing from rewinder. - Refer for the next steps to point 1. of “Label Loading” (see page 23) Out of Operation Never take the applicator out of operation while it dispenses a label.
Page 26: Inputs / Outputs
Chapter 4 Inputs / Outputs ALPHA V40 4. Inputs / Outputs This chapter covers the connections of controller and input configuration of Overview sensors. CAUTION!! Any setup procedure of this chapter should only be performed by a qualified service technician! Connections on rear panel See explanations for any connection (shown on Fig.
Page 27: Connection To Ac Power (230 / 115 Vac)
Chapter 4 Inputs / Outputs ALPHA V40 Connection to AC Power (230 / 115 VAC) Please read these notes before connecting the display controller to the AC power! Note: This applicator is designed for interference free voltage of 115 /230 VAC, (configurable).
Page 28: Configuration Of The Input Power (230Vac Or 115Vac)
Chapter 4 Inputs / Outputs ALPHA V40 Configuration of the Input Power (230VAC or 115VAC) The default setting of the applicator is 115 VAC (60Hz, Fuse: T 4 Ampere) for USA requirements and 230 VAC (50Hz, Fuse: T 2 Ampere) for Europe. A sticker located on the power inlet informs you about the values of voltage, supply frequency and fuse.
Page 29: Enclosure Cover Removal / Installation
Chapter 4 Inputs / Outputs ALPHA V40 Enclosure Cover Removal / Installation This procedure should be followed every time the enclosure cover is removed and installed. The enclosure cover must be removed in order to configure product sensors. Removal 1. Disconnect the AC power cord from controller rear panel. 2.
Page 30: Product Sensor Connection (X2-Product Sensor P, X4-Product Sensor S)
Chapter 4 Inputs / Outputs ALPHA V40 Product Sensor Connection (X2-PRODUCT SENSOR P, X4-PRODUCT SENSOR S) The ALPHA V40 contains five M12-connectors (Refer to Fig. 4-1 on page 26), which matches to industrial standards. Two inputs are used to connect Product Sensors P (primary) and Product Sensors S (secondary).
Page 31 Chapter 4 Inputs / Outputs ALPHA V40 Use the plastic shunts (actually contain metal for bridging two pins of jumper) for the configurations. The possible settings are shown on the table as follows: Fig. 4-5: without enclosure cover (top view) Jumper setting Config.
Page 32 Chapter 4 Inputs / Outputs ALPHA V40 Configurations for Standard Sensor Types: Banner: Minibeam-Expert, SMe312DQDP >>> sensor config. 6 und 7 Balluff: Reflextaster BOS 18M-NA-1QB-5 >>> sensor config. 5 und 6 Wenglor: Reflextaster TC 55NA3 + Zub-TC-01 >>> sensor config. 5 und 6 Wenglor : Retroreflective sensor LD86PCT3 >>>...
Page 33: Low Label Sensor Connection (X3-Low Label Sensor)
Chapter 4 Inputs / Outputs ALPHA V40 Low Label Sensor Connection (X3-LOW LABEL SENSOR) Refer to Fig. 4-1 on page 26. One of the M12 Connectors on the rear panel requires to the option “Low Label Sensor”. If this option is connected, it is ready for use. Its input is also configurable but it is not necessary in the normal case.
Page 34: Warning Lights Connection (X6-Alarm Lamp)
Chapter 4 Inputs / Outputs ALPHA V40 Warning Lights Connection (X6-ALARM LAMP) There is no additional equipment required than the alarm option itself to use this feature. If the warning lights are connected to the 8-pin M12 Connection on controller rear panel (refer to Fig.
Page 35: Label Sensor Connection (X7-Label Sensor)
Chapter 4 Inputs / Outputs ALPHA V40 Label Sensor Connection (X7-LABEL SENSOR) The controller rear panel obtains a DB15S plug (refer to Fig. 4-1 on page 26), to connect the label sensor from the machine. This special photo cell detects the gap between the labels in way of opacity reading.
Page 36: Relay Outputs (X9-Relay-Outputs)
Chapter 4 Inputs / Outputs ALPHA V40 Relay Outputs (X9-RELAY-OUTPUTS) This is also a standard connector which can use for monitoring the conditions of ALPHA V40. It is used to synchronize conveyer PLCs to the application sections in order to apply labels with an exact timing.
Page 37: Ready Relay (Outputs Of X9)
Chapter 4 Inputs / Outputs ALPHA V40 READY Relay (Outputs of X9) When the controller is in normal operating conditions the READY relay is active and the warning lights (if fitted) appears green. The relay is deactivated when an error occurs or the user changes the display controller into an edit mode (e.g.
Page 38: Machine Setup
Chapter 5 Machine Setup ALPHA V40 5. Machine Setup This chapter covers the setup procedures for the label applicator. These Overview procedures include label and tamp adjustments and air pressure settings. This chapter also includes operational tests. Some of these procedures require the machine to be powered and the air pressure applied.
Page 39: Unwind Brake Adjustment
Chapter 5 Machine Setup ALPHA V40 Unwind Brake Adjustment NOTE: The unwind brake adjustment should only be performed by a qualified service technician! This procedure sets the tension on the dancer arm brake. Use the following instructions to adjust the tension of the unwind dancer arm brake: Fig.
Page 40 Chapter 5 Machine Setup ALPHA V40 6. Install the inner unwind disk and label roll support 7. Install the label roll and push the outer unwind disk close to the roll. 8. Load the label liner for an operational test 9.
Page 41: Positioning Label Sensor
Chapter 5 Machine Setup ALPHA V40 Positioning Label Sensor In exceptions the detection of a label edge can be problematically in spite of calibration. In this case choose a position where the photocell reads the clearest area of the label (if printed) to evaluate the transparency of backing and label avoiding the risk of being fooled by possible alternating dark and clear areas on pre-printed labels.
Page 42: To Setup The Mechanical Label-Sensor (Option)
Chapter 5 Machine Setup ALPHA V40 To Setup the Mechanical Label-Sensor (Option) NOTE: Following adjustments should only be performed by a qualified service technician! This label detection is generally used for transparency labels. In the opposite to the standard label sensor reading the opacity of different label types, this one scans the thickness of the material using an inductive sensor and a mechanical lever.
Page 43: Wipe-On Setup
Chapter 5 Machine Setup ALPHA V40 Wipe-On Setup There are two adjustments which can be made to the roller: the distance between the edge of peeling blade to the roller the alignment of the roller to the surface of products Note! The distance A should be increased in general for longer labels.
Page 44: Applicator Setup
Chapter 5 Machine Setup ALPHA V40 Applicator Setup Air Assist Setup NOTE: Following adjustments should only be performed by a qualified service technician! All ALPHA V40 work with the air assists except the Wipe-On systems. For the label application a label must be pressed against the tamp pad/ vacuum grid, till it is captured by the vacuum.
Page 45 Chapter 5 Machine Setup ALPHA V40 Press the [Enter] key at the controller panel to feed a label to check your setup. If the vacuum does not catch label increase the air assist pressure and feed another label. Continue to increase the air assist pressure until the tamp/grid vacuum catches the label. Only labels with large sizes or heavy weights require a higher setting.
Page 46: Blow-Box Setup
Chapter 5 Machine Setup ALPHA V40 Blow-Box Setup This part covers the setup for ALPHA V40 with blow box at first. (in the following see information for adjustment procedures for the tamp applicators). Fig. 5-7: V40 with Blow Box Vacuum Adjustment Turn the orifice plate located on the upper side of the blow box to rule the amount of emitting air.
Page 47: Vacuum Box Grid Setup
Chapter 5 Machine Setup ALPHA V40 Vacuum Box Grid Setup NOTE: The setup should only be performed by a qualified service technician! The vacuum box (100 x 100 mm) contains 18 flexible tubes that provide the blast of air to apply the label to the product.
Page 48: Air Blast Tube Arrangements
Chapter 5 Machine Setup ALPHA V40 Air blast Tube Arrangements Fig. 5-10: Several Air Blast Tubes Arrangements Version 18.07.06...
Page 49: Tamp-Blow Setup
Chapter 5 Machine Setup ALPHA V40 Tamp-Blow Setup Includes the explanations of all relevant procedures to setup the optional Tamp Blow applicators. NOTE: The setup should only be performed by a qualified service technician! Vacuum Setup The vacuum is used to hold the label under the tamp plate and it’s adjustable by using a flow control valve.
Page 50: Piston Speed Setting
Chapter 5 Machine Setup ALPHA V40 Piston Speed Setting NOTE: Following adjustments should only be performed by a qualified service technician! The speeds of extension and retraction from the tamp pad are set using two air flow control valves. These regulators are positioned at the ends of the cylinder unit. The flow controls are factory pre-set.
Page 51: Home Sensor Adjustment
Chapter 5 Machine Setup ALPHA V40 Home Sensor Adjustment NOTE: Following adjustments should only be performed by a qualified service technician! The Home Position Sensor is used for the tamp presence check. The home position is located where a label is ejected to the tamp plate. From this position the tamp extents to the product to apply a label.
Page 52 Chapter 5 Machine Setup ALPHA V40 3. Adjust the home position sensor required until the „H“ appears in the controller display. Fig. 5-13: Home Sensor Adjustment 4. Tighten the threaded pin and check your adjustment (refer to description on page 51) and repeat the procedure as needed.
Page 53: Tamp Pad
Fig.5-14: Tamp Pad Depending on the employment of the machine, the tamp pad is delivered separately by the system. You receive the individually pad with accurate hole design from Weber Marking Systems. CAUTION ! Never run the applicator with a tamp pad without drilling holes.
Page 54: Installation Of Tamp Pad
Chapter 5 Machine Setup ALPHA V40 5. The minimum number of drilling holes, for particularly small label sizes is 8 till 9 holes (e.g. 2 x 4 or 3 x 3). Up to 70 drilling holes (e.g. 8 x 6) can be required for very large labels (170 x 120 mm).
Page 55: Proximity Sensor For Variable Stroke (Option)
Chapter 5 Machine Setup ALPHA V40 Proximity Sensor for Variable Stroke (Option) NOTE! This procedure should only be performed by a qualified service technician. This Proximity Sensor is used in touch with a tamp applicator only. A V40 using this option obtains the possibility to a apply labels contactless onto products with different heights.
Page 56: Tamp-On Setup
Chapter 5 Machine Setup ALPHA V40 Tamp-On Setup All settings of ALPHA V 40 equipped with the optional Tamp Blow Applicators apply nearly exactly the same as systems with Tamp On Applicators. The exception is the construction of the spring mounted (Gimbal-) Tamp, which is designed to press the label onto the product.
Page 57: Product Detection Setup
Chapter 5 Machine Setup ALPHA V40 Product Detection Setup This part covers the setup and adjustment procedures for the product detector. It explains how to position the applicator and adjust its sensitivity. Positioning the Applicator The applicator needs to be in a position to properly apply a label to the product. Make sure that all the moving parts have enough clearance to avoid any obstacles in the area and refer to setup information of the respective applicator on the pages before.
Page 58: Test Run
Chapter 5 Machine Setup ALPHA V40 Fig. 5-18: Product Detector/Reflector Alignment 2. Position the product detector so that it is even with (or slightly upstream from) the leading edge of the product (or trailing edge if you set the product edge detection to trailing). 3.
Page 59: Display Controller
Chapter 6 Display-Controller ALPHA V40 6. Display Controller This chapter describes all the functions in the controller and panel keys, how Overview to use them to adjust the applicator, and the different menu screens available from the control panel. This chapter also includes error codes for assistance in troubleshooting the machine.
Page 60: Label Counter
Chapter 6 Display-Controller ALPHA V40 In normal operating conditions, the display shows information as explained below Input sensor (status) Label sensor Label counter (value and state) (0000 to 25 599) 0000XHEPSL 123G 0123mm 12.3 Current label ID Feed speed [m/min] (01 to 30) Trigger delay Feed length...
Page 61: Current Label Id
Chapter 6 Display-Controller ALPHA V40 Current Label ID The left position of second line displays the currently selected label ID number. It can range from 01 to 30. Each value represents complete label parameters of corresponding stored label settings. Feed Length …...
Page 62: To Enter Menus
Chapter 6 Display-Controller ALPHA V40 To Enter Menus The ALPHA V40 controller contains three menus which can be reached by different key combinations. Please, press them always simultaneously: USER MODE ] + [Enter] = PROGRAMMING MODE [Enter] + [ SERVICE MODE ] + [ password protected NOTE: SERVICE MODE should only be used by a qualified service technician!
Page 63 Chapter 6 Display-Controller ALPHA V40 This flow chart shows how to use the control panel keys to navigate through the menus in the controller. Version 18.07.06...
Page 64: User-Menu
Chapter 6 Display-Controller ALPHA V40 User-Menu The User Menu contains basic functions of the daily expenditure only. See utilities as follows: - LABEL FORMAT - RESET COUNTER - CHANGE LANGUAGE Press [ ] and [Enter]-keys simultaneous, until the following screen displays: 0000 123G LABEL FORMAT 01...
Page 65: Reset Counter
Chapter 6 Display-Controller ALPHA V40 RESET COUNTER In the left top position of the display there is a counter which counts the dispensed labels. The maximum value is “25599”. If the maximum is reached, the counter changes to the start value „0000“.
Page 66: Programming Mode
Chapter 6 Display-Controller ALPHA V40 Programming Mode The ALPHA V40 contains up to 30 different label formats (how to change, see page 64). You are able to call up every parameter of a stored label format. In the Programming Mode the current label format is displayed on the rightmost position of the first line.
Page 67: Auxiliary Information To The Line Speed
Chapter 6 Display-Controller ALPHA V40 value is temporary and is not stored in memory until PROGRAMMING mode is entered and the STORE PARAMETERS function is executed. Auxiliary information to the Line Speed Up to 10 m/min the stepper motor can start and stop instantly, so the speed is constant for the entire movement.
Page 68: Label Position
Chapter 6 Display-Controller ALPHA V40 LABEL POSITION Select “Label Pos.” specified the position where the edge of the next label stops on the peeling blade. If the machine is correctly configured and calibrated, the value “00” corresponds to a label position few millimetres before end of the peeling blade (see Fig. 6-3). The Label Position can range from 0 to 127 with a maximum distance of 38 mm.
Page 69: Referenc Edge
Chapter 6 Display-Controller ALPHA V40 REFERENC EDGE This parameter defines the edge of the label that must be used for label alignment. Value “00“ selects leading edge, and “01” trailing edge. Two cases of a meaningful set up: Fig. 6-4 a) The choice of a straight label edge may result in more precise positioning than the edge of odd shape labels (see Fig.6.4).
Page 70: Gap Level
Chapter 6 Display-Controller ALPHA V40 GAP LEVEL The gap between labels is detected when the photo sensor reads a value lower than this parameter. It is automatically set by the sensor calibration procedure. In special cases a manually set is possible (see its description for a practical rule to set this parameter, page 73). PROGRAMMING GAP LEVEL: Press either [...
Page 71: Trigger Delay
Chapter 6 Display-Controller ALPHA V40 TRIGGER DELAY This function allows the exact positioning of a label without moving the product sensor. It delays from trigger activation to the start of motor movement. The time delay is a dynamic parameter and depends on the LINE SPEED (refer page 66). For speeds up to 20.99 m/min its parameter is 10 ms per unit, while for 10.0 m/min and above it changes to 1 ms per unit, thus improving label placement resolution.
Page 72: Trigger Blank
Chapter 6 Display-Controller ALPHA V40 TRIGGER BLANK Products of irregular shape may have their unwanted multiple trigger signals masked out. This additional delay starts at the end of a label ejection, during which the trigger signal is being ignored. If "burst" mode is selected (see page 85), this parameter controls the spacing between the first label and the following ones in the sequence.
Page 73: Calibrate Sensor
Chapter 6 Display-Controller ALPHA V40 CALIBRATE SENSOR “Calibrate Sensor” is used to read different values of label material and needed to detect the label edge, the backing paper (carrier tape) and to determine paper out. PROGRAMMING CALIBRATE SENSOR Press either [ ] or [ ] key to move to the next setting.
Page 74: Calibrate Label
Chapter 6 Display-Controller ALPHA V40 CALIBRATE LABEL “Calibrate LABEL” is used to measure the label length. While the procedure, one or two labels ejecting (depending if it starts on the gap or on the label) with predefined speed of 10 m/min. During this movement, the distance between the reference edges of two adjacent labels is measured and will be used as a reference for label ejection during normal operation.
Page 75 Chapter 6 Display-Controller ALPHA V40 STORE PARAMETERS It is need to terminate the Programming Mode and stores the current values of the operating parameters in non-volatile memory. Also the ALPHA V40 comes into READY conditions. PROGRAMMING STORE PARAMETERS Press either [ ] or [ ] key to move to the next setting.
Page 76: Service Program
Chapter 6 Display-Controller ALPHA V40 Service Program This program is also a password protected menu to setup fundamental parameters of the machine and should only be used by a qualified service technician. It offers the possibility to read or overwrite any location of the memory. To enter or to leave the Service Program press the following key combinations simultaneous: ] + [ ] = SERVICE PROGRAM...
Page 77: Address 00 (Page 0), Language
Chapter 6 Display-Controller ALPHA V40 Please use these key handlings for moving and editing Service Mode basically. SERVICE PROGRAM 0 00= 00 Press either [ ] or [ ] key to move to the next Address. Use the [Enter]-key to edit the parameter. The [ ] and [ ]-keys increase or decrease the value.
Page 78: Address 02 (Page 0), Trigger/Applicator Configuration
Chapter 6 Display-Controller ALPHA V40 Address 02 (Page 0), trigger/applicator configuration This location is used to select the way how to combine any trigger input of “primary” and “secondary” sensors for controlling the applicator. With the consequence that the values of any combination have to be calculated (add up).
Page 79: Address 04 (Page 0), Max. Search Length
Chapter 6 Display-Controller ALPHA V40 Address 04 (Page 0), max. search length SERVICE PROGRAM 0 04= 50 0 04 = Value for currently selected of maximum search length in cm for label edge during calibration 00 - 255 = (default 50) If in the selected length there is no label edge detected the calibration procedure is interrupted.
Page 80: Address 06 (Page 0), Encoder Reading
Chapter 6 Display-Controller ALPHA V40 Address 06 (Page 0), encoder reading Here is made the entering of the impulse length of the connected shaft encoder. To enable the variable labelling choose "0.4" at Address 08 (optional at "LINE SPEED" in Programming Mode).
Page 81: Address 07 (Page 0), Diagnostic Functions
Chapter 6 Display-Controller ALPHA V40 Address 07 (Page 0), diagnostic functions This parameter contains diagnostic functions which can be set with entering its value. If some functions should be combined, please enter their calculated sum. SERVICE PROGRAM 0 07= 00 0 07 = Values of each diagnostic functions (Values represent true or false bits).
Page 82: Address 08 (Page 0), Dispensing Speed (Of Label Format #1)
Chapter 6 Display-Controller ALPHA V40 The next block of eight addresses belongs to the label format 01. NOTE: For each label format (30) exists a block with same addresses and parameters. In the matter of fact this is renounced to repeat all addresses for each label. So that address 08 represents the address 16 (of label format 02), also 24 (of label format 03)…...
Page 83: Address 12 (Page 0), Trigger Delay (Of Label Format #1)
Chapter 6 Display-Controller ALPHA V40 Address 12 (Page 0), trigger delay (of label format #1) 0 12 = Value for currently selected trigger delay 00 – 255 = TRIG. DELAY Address 13 (Page 0), sync pulse (of label format #1) 0 13 = Value for currently selected sync pulse 00 –...
Page 84: Address 249 (Page 0), Tamp Extension Time
Chapter 6 Display-Controller ALPHA V40 Address 248 (Page 0), home detection timeout This parameter is only used to be in touch with a tamp applicator, which contains a sensor for locating that the piston is completely retracted. Its delay has to contain the retract time of tamp. 0 248 = Value for currently selected the timeout for home detection.
Page 85: Address 251 (Page 0), Blow Time
Chapter 6 Display-Controller ALPHA V40 Address 251 (Page 0), blow time The blow valve is activated possibly following a trigger signal from the secondary product sensor (selected by bit 2 of parameter at address 02) after the previous time is elapsed for a duration specified by this parameter.
Page 86: Address 254 (Page 0), Access Code
Chapter 6 Display-Controller ALPHA V40 0 253 = Value for currently apply delay (Default 00) 00 = no delay 01 – 255 = value x 10ms NOTE ! The following functions apply when using the Firmware-Version 40.5c (for High speed applications) Providing compensation enabled adjusting to equal response behaviour of parallel working systems.
Page 87: Set Up Alpha V40 To Applicators
Chapter 6 Display-Controller ALPHA V40 Set Up ALPHA V40 to applicators All setup examples correspond to Address 0 02 (see page 78) and show the common variants in connection with the used applicator type (Option). Set up V40 to Tamp-On Applicator Address 0 02 Byte 0 02 value...
Page 88: Set Up V40 To Tamp-Blow Applikator
Chapter 6 Display-Controller ALPHA V40 Set up V40 to Tamp-Blow Applikator Address 0 02 Byte 0 02 value Input value System - Blow - Box P-sensor starts the label feed. S-sensor starts the tamp extension and air blast of the label The label is feed automatically subsequent tamp extended.
Page 89: Set Up V40 To Blow-Box Applikator
Chapter 6 Display-Controller ALPHA V40 Set up V40 to Blow-Box Applikator The S-sensor (if the secondary sensor is connected appears a “S”) is designated to start the application via blow-box-/ or Tamp Address 0 02 Byte 0 02 value Input value System - Blow - Box S-sensor starts the air blast of the “waiting”...
Page 90: Quick Descriptions Of Most Important Functions
Chapter 6 Display-Controller ALPHA V40 Quick descriptions of most important functions To call up stored Label Formats USER MENU ] + [Enter] [Enter] "LABEL FORMAT …" ] oder [ "LABEL FORMAT: XY " choose the desired Label Format [Enter] confirm alternation To setup (new) Types of Labels Load the label roll see description on page 23...
Page 91: To Setup The Label Position
Chapter 6 Display-Controller ALPHA V40 To setup the Label Position Caution! Keep hands away! Feed 2-3 labels to determine the [Enter] Feed a label distance D from peeling-blade to the label edge PROGRAMMING MODE [Enter] + [ ] oder [ "LABEL POS.
Page 92: Table Of Parameters
Chapter 6 Display-Controller ALPHA V40 Version 18.07.06...
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Page 95: Firmware Release Notes
Chapter 6 Display-Controller ALPHA V40 Firmware Release Notes Following is a history of firmware releases through version 40.0 Version 40.5c Released: 12 May 2005 A special Firmware version valid for High-Speed Applicators (normally used with Blow-Box) only. Minimal response time for Secondary Sensor (X4) (trigger air blast when label waits on the Blow-Box).
Page 96 Chapter 6 Display-Controller ALPHA V40 a keypad diagnostic function is activated if any key is pressed at switch-on roll-over capability in edit-mode now allows to jump directly from min to max value (and viceversa) of any parameter without having to scroll the entire range the key-combination Left+Right is recognized while in error condition to go directly in Service Mode the key-combination Left+Enter is recognized in Service Mode to advance the current...
Page 97 Chapter 6 Display-Controller ALPHA V40 for internal validation Version 40.2 Released: 26 September 2003 The main difference over the previous firmware version is the capability to drive an external pneumatic applicator, whose valves and sensors are connected to the 9-pin "D" socket present on the rear panel.
Page 98: Maintenance
Chapter 7 Maintenance ALPHA V40 7. Maintenance This section gives instruction for performing maintenance on the label Overview applicator ALPHA V40. The ALPHA V40 is a reliable, modern system to operate without any maintenance required because of the self lubricating bearings used. You should only care for immediate removal of any dirt deposits resulting from daily operation - such as e.g.
Page 99: Daily Maintenance
Chapter 7 Maintenance ALPHA V40 Daily Maintenance 1. Clean platen roller each time you change the Label roll. 2. Examine the tamp, vacuum grid, and peeler bar for excessive adhesive build up. Clean if necessary, using alcohol or some other similar solvent. 3.
Page 100: Weekly Maintenance
Chapter 7 Maintenance ALPHA V40 Weekly Maintenance 1. Clean the peeler bar, vacuum grid, and tamp pad using alcohol or some other similar, compatible solvent. 2. Clean dust from the product detector and low label sensor lenses. NOTE: Do not use air pressure from the shop air supply to blow dust from the machine. There is a possibility that this air can contain water and emulsified oil, which can damage the electrical components in the machine.
Page 101: Six-Month Maintenance
Chapter 7 Maintenance ALPHA V40 Six-month Maintenance 1. Replace the air filter elements and clean the filter bowl. NOTE: Do not use air pressure from the shop air supply to blow dust from the machine. There is a possibility that this air can contain water and emulsified oil, which can damage the electrical components in your machine.
Page 102: Yearly Maintenance
Chapter 7 Maintenance ALPHA V40 Yearly Maintenance 1. Check all the items in the weekly and six-month maintenance sections. 2. Examine moving parts for excessive wear. 3. Check the brake strap for wear and proper tension. Version 18.07.06...
Page 103: Troubleshooting
Chapter 8 Troubleshooting ALPHA V40 8. Troubleshooting This chapter covers diagnostic and troubleshooting information. It explains Overview how to use the built-in diagnostic tools and covers common problems, possible causes and solutions. NOTE: The following diagnostics relates to all applicator versions and contains also optionally Items (Alarm Lamp, Speed Encoder, Low Label Option,…) Errors of mechanical causes PROBLEM...
Page 104 Chapter 8 Troubleshooting ALPHA V40 PROBLEM POSSIBLE CAUSE SOLUTION Label placement on the Incorrect blow time. Refer to the Setup Instructions on product consistently poor. (if a tamp or blow-box page 85 applicator is installed) Product detector sensitivity Refer to Sensor Manual out of adjustment.
Page 105 Chapter 8 Troubleshooting ALPHA V40 PROBLEM POSSIBLE CAUSE SOLUTION Machine functions occur at Product detector loose or Refer to setup instructions random without being vibrating. on page 57 initiated. Product detector alignment or adjustment is marginal. Loose wiring connections. Check wiring connections.
Page 106: Error Messages Appearing On Display
Chapter 8 Troubleshooting ALPHA V40 Error Messages Appearing on Display When an operating problem or an error is detected, the machine stops, the READY and SYNC relays are deactivated and the second line shows an explanatory message: 0123 123G NO PAPER The error condition is reset by pressing any key, to return in normal operating mode and activates the READY relay again.
Page 107 Chapter 8 Troubleshooting ALPHA V40 DISPLAY-MESSAGE POSSIBLE CAUSE SOLUTION NOT RESPONDING indicates internal It maybe caused by a loose communication problem connection, fault strong between the controller and electromagnetic interference the motor driver. Check all wiring connections. If necessary request qualified assistance (Hotline support, refer to page 13).
Page 108: Additional Information For A Advanced Assistance
Chapter 8 Troubleshooting ALPHA V40 Additional information for a advanced assistance When the primary or the secondary product sensor input changes from the inactive to the active state while the other is inactive (current begins to flow into the optocoupler due to an applied voltage), the following actions are performed in sequence: 1) waits for the time specified by the TRIGGER DELAY parameter;...
Page 109: Index
Chapter 9 Index ALPHA V40 9. Index AC POWER CONNECTION 27 DIRECT-TAMP-MODE 18 ACCESS CODE 62 DISPLAY CONTROLLER 59 AIR ASSIST 6 ELECTRICAL POWER 14 AIR ASSIST SETUP 44 ENCLOSURE COVER AIR JET 44 REMOVAL/INSTALLATION 29 AIR PRESSURE CONNECTION 14 ENCODER 33, 80, 106 ALARM LAMP 34 ENTER MENUS 62...
Page 110 Chapter 9 Index ALPHA V40 LINE SPEED 67 SPARE PARTS 9 LINE SPEED 66 SPECIFICATIONS 14 LOW LABEL RELAY 37 STEPPER MOTOR CONNECTION 29 LOW LABEL SENSOR 33 STORE PARAMETERS 75 MACHINE POSITION 15 SYNC PULSE 71 MACHINE SETUP 38 SYNC RELAY 37 MACHINE STAND 15 TAMP ADJUSTMENT 50...
Page 111: Declaration Of Conformity
Chapter 10 Declaration of Conformity ALPHA V40 Declaration of Conformity LetzteSeite Version 18.07.06...

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