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Novexx Solutions ALS 30 Series Installation Manual

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INSTALLATION MANUAL
ALS 30x
Labeler
Edition 6 - 7/2024 - Translation of original version

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  • Page 1 INSTALLATION MANUAL ALS 30x Labeler Edition 6 - 7/2024 - Translation of original version...

  • Page 3: Table Of Contents

    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 Functions Function menu Overview Notes on the description of functions LABEL SETUP menu MACHINE SETUP menu INTERFACE PARA menu Submenu >EASYPLUGINTERPR Submenu >COM1 PORT Submenu >NETWORK PARAM. SIGNAL INTERFACE Submenu >PLC SIGNALS Submenu >APPLIC. SIGNALS Submenu >AI BOARD SIGNAL Submenu >AI BOARD SIGNAL Submenu >ACTIVE INPUTS SERVICE/DIAGNOS.
  • Page 5 ALS 30x Installation Manual Enhanced Functions -111 Access via a Web/FTP server -111 Web server -111 FTP server -115 Saving/loading a configuration -117 Applications -117 Saving onto an external memory medium -117 Loading from an external memory medium -118 Automatic loading -119 Loading a configuration via the data interface -119...
  • Page 6 ALS 30x Installation Manual 07/2024 Contents...

  • Page 7: Please Observe The Following

    14. 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 8 ALS 30x Installation Manual Manufacturer Novexx Solutions GmbH Ohmstraße 3 D - 85386 Eching Phone: +49-8165-925-0 FAX: +49-8165-925-231 www.novexx.com 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.

  • Page 9: Notes On Installation And Repair Work -9

    ALS 30x Installation Manual Functions Functions are printed in grey text, in the form NAME OF MENU > Name of function Supplemental information The information symbol indicates notices and recommendations as well as additional helpful information. Auxiliary materials: – Auxiliary materials, e.g. lubricants, glues or cleaning agents Tightening torques: –...
  • Page 10 ALS 30x Installation Manual Eco-friendly disposal: Sort the waste as much as possible, e.g. separate metals from plastics.   Avoid contaminating the waste if possible.  Drop off the waste at the collection points provided for that purpose  Have the waste collected by suitable recycling agencies.
  • Page 11 ALS 30x Installation Manual  Only shield both sides when the grounding conditions are the same (e.g. inside a machine). 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 cable: –...

  • Page 12: Safety Instructions -12

    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 13: Machine Operating Safety -13

     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 14: Safe Operation -14

    ALS 30x Installation Manual Protection measures in applicator mode WARNING! Danger of crushing between dispenser edge and applicator pressure plate due to applicator movement!  Prevent personnel from reaching between dispensing edge and applicator by installing high- er-level protective equipment 1) Movable, separating guards according to EN 953 After all servicing or repair work WARNING!
  • Page 15 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 16: Technical Data -16

    ALS 30x Installation Manual Technical Data DIMENSION DIAGRAMS ALS 306: 477 ALS 309: 539 22,6 71,25 [443]Dimensions ALS 30x - Part 1 07/2024 | 00 Technical Data...
  • Page 17 ALS 30x Installation Manual [444]Dimensions ALS 30x - Part 2 07/2024 | 00 Technical Data...

  • Page 18: Installation And Deinstallation -18

    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 [445] to [450] show the possible operatio- nal positions of an ALS 30x with two unwinders for top labelling.
  • Page 19 ALS 30x Installation Manual Vertical position [448]Vertical mounting position for top labelling. [450]Vertical mounting position for top labelling. [449]Vertical mounting position for top labelling. 07/2024 | 00 Installation and Deinstallation...

  • Page 20: Side Labelling -20

    ALS 30x Installation Manual Side labelling The pictures [451] to [456] show the possible operatio- nal 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 21 ALS 30x Installation Manual Vertical position [456]Vertical mounting position for side labelling. [454]Vertical mounting position for side labelling. [455]Vertical mounting position for side labelling. 07/2024 | 00 Installation and Deinstallation...

  • Page 22: Unpacking, Assembling And Connecting The Machine -22

    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 23 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 24 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° [460]Adjustable head joint, assembled max.
  • Page 25 ALS 30x Installation Manual Assembly Turn the adjustment screw [466A] and both clamp  screws [466C] some rotations out. [466] Machine side bracket ready mounted.  Insert the support stand side bracket [467A] and push in the axle [466B] flush. [467] Assembling the support stand side bracket (A).
  • Page 26 ALS 30x Installation Manual Holding machines in place with the flange plate – Order number for flange plate assembly [470C] (in- cluding screws and washers): A7622 Tool: – 8/10 mm hexagon socket driver  Screw the flange plate [470C] to the appropriate flange at the machine.
  • Page 27 ALS 30x Installation Manual Mounting the unwinder Tools: – 8 mm allen key Prerequisites: Depending on the planned application, the ALS 30x comes with one or two unwinder(s). For recommended respectively admissible combinations, see chapter “Admissible operation positions” auf Seite 27. Rewinder position Article number Left side...
  • Page 28 ALS 30x Installation Manual [473]Mounting the unwinder (A). Fix the unwinder to the flange using the 4 screws  [473B] and washers that came with the unwinder, but only tighten the screws by hand. CAUTION! Possible unproper machine function caused by inaccurate alignment during assembly.
  • Page 29 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 [475]Short dispensing edge holder with one mounting point and fixed L-shape dispensing edge.
  • Page 30 ALS 30x Installation Manual Installing a short dispensing edge holder with one mounting point Mounting angle = 0°:  Swivel the dispensing edge holder to the required angle and screw it to the mounting point. – The screw [477B] can be reached through the hole in the top cross beam.
  • Page 31 ALS 30x Installation Manual Installing a dispensing edge holder with 2 mounting points Mounting angle = 0°:  Screw the dispensing edge holder to the 2 mounting points [480A] using the 2 screws [480B]. – The screws can be reached through the holes in the cross beams.
  • Page 32 ALS 30x Installation Manual Mounting the deflection rollers: Remove the AUM, see chapter “Removing the  AUM” auf Seite 255.  Remove the cap [482C].  Remove the existing deflection roller [482A] and mount it on the opposite side of the base plate [482B].
  • Page 33 ALS 30x Installation Manual Mounting the Euro dispensing edge holder The Euro dispensing edge holder is mounted in the same way as the long dispensing edge holder - with one difference: For horizontal mounting to a RH machine, the cross bars can not be turned as easily as with the long dispensing edge holder.
  • Page 34 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 35 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 36 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 hou- sing [490].
  • Page 37 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 [492] Article numbers: – A101974: Sensor with bracket and cable (1.5 m) –...
  • Page 38 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 [494] Connection diagram for photoelectric label sensor The LED current at pin 2 controls the sensitivity of the sensor.
  • Page 39 ALS 30x Installation Manual Teaching the sensor  Press the button [495A] for 2 s, until the status LEDs [495B] light permanently. – Notice: Don´t press the button for longer than 5 s, otherwise you risk to switch between NO/NC , see chapter Switching the Novexx sensor - NC/NO ...
  • Page 40 ALS 30x Installation Manual Switching the Novexx sensor - NC/NO This light sensor is equipped with a push-pull output stage, thus, the two states are called NO (normally open) and NC (normally closed). Default setting: NC Switching between NC/NO:  Press the button [498A] for at least 6 s, until the sta- tus LEDs [498B] flash 2x.

  • Page 41: Capacitive Label Sensor -41

    MACHINE SETUP > done by calling the function Label sens. type. The setting is stored within the product profile. NOVEXX Solutions offers a capacitive label sensors from di-soric (www.di-soric.de). Article numbers: – N104308 Capacitive sensor di-soric KGUTI50 0.4-G3-T4 [499] – Sensor kit (sensor + sensor holder + connection...
  • Page 42 ALS 30x Installation Manual Installation Tools: – Hexagon socket drivers 4/6 mm  Turn out screw [502C] and remove the dispensing edge [502E].  Remove the screws [502F] from the bottom ends of the holding rods. Take off the dispensing edge holder D].
  • Page 43 ALS 30x Installation Manual Connecting the sensor  Plug the sensor to the connector [505A]. Connection accessories Article no. Connector A8142 Connecting cable (coupling-plug) A7127 Pin assignment Assignment +24 V +24 V or ground or no [505] Connection (A) for alternative label sensor connection Ground Sensor signal...
  • 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) [506] Connection diagram alternative label sensor. Jumper descrip- tion see Changing light/dark switching at the product sensor or the alternative label sensor ...
  • Page 45 ALS 30x Installation Manual Static „single value teach“ on label gap: Position the sensor with the detection area over a la-  bel gap and fix it there. – It is best to remove a label and slide the sensor over the resulting gap.

  • Page 46: Changing Light/Dark Switching At The Product Sensor Or The Alternative Label Sensor -46

    ALS 30x Installation Manual Changing light/dark switching at the product sensor or the alternative 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: Start (Product) Sensor -47

    ALS 30x Installation Manual Start (product) sensor The start sensor (= product sensor) starts the dispen- sing process and is therefore indispensable in most applications. These installation instructions refer to the standard sensor (N102106) [513] offered by Novexx. Alternatively, a sensor with reflector is available (N102109).
  • Page 48 ALS 30x Installation Manual Pin assignment Assignment +24 V +24 V or ground or no connection Ground Sensor signal Changing light/dark switching at the product sensor or the alternative label sensor  on page 46 Connection Diagram +24V +24V NPN-Configuration 2,2k NPN-Signal 1,5k...

  • Page 49: External Roll Diameter Sensor -49

    ALS 30x Installation Manual External roll diameter sensor [518] External OD sensor. The ALS30x can be equipped with an optional sensor [518] 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 50 ALS 30x Installation Manual Connecting  Plug the roll diameter sensor in to the connector shown [519 arrow]. Alternatively, the OD sensor can be connected to the optional applicator interface (see service manual, assignment for applicator connection  on page 210). Enabling MACHINE SETUP >...
  • Page 51 ALS 30x Installation Manual Pin assignment Assignment +24 V not used Ground Sensor signal [Tab. 93] 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 52 ALS 30x Installation Manual Function test Prerequisite: – Machine is in dispensing mode. MACHINE SETUP > OD sensor warn. – = „Warning“ (set- tings according to Enabling  on page 50). If the light beam of the sensor [521C] meets the reflec- tor, the following warning appears after the next label has been dispensed: ONLINE...

  • Page 53: Internal Od-Sensors -53

    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 54 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 55: Rotary Encoder -55

    N103707 Mounting kit [526] Novexx encoder (C) with measuring wheel (A) and bracket [Tab. 95] Article numbers for Novexx rotary encoder and (B) for mounting on a Novexx Solutions conveyor belt. accessories. 07/2024 | 00 Installation and Deinstallation...
  • Page 56 ALS 30x Installation Manual Article no. Article Image N103709 Rotary encoder kit N103696 Rotary encoder N103697 Measuring wheel (200 mm circumfe- rence, for 10 mm axle) N101829 Connection cable (2m) [Tab. 95] Article numbers for Novexx rotary encoder and accessories. Connecting the rotary encoder CAUTION! To avoid damage to the electronics:...
  • Page 57 ALS 30x Installation Manual Connection diagram +24V +24V 3,8k Signal A Signal A Input 3,8k Signal B Signal B [530] Connection diagram rotary encoder 07/2024 | 00 Installation and Deinstallation...

  • Page 58: Installing Options -58

    ALS 30x Installation Manual INSTALLING OPTIONS 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 59 ALS 30x Installation Manual – The slot in the insert must be placed on the same side as the slot between the two housing halves.  Feed the operator panel cable [533C] through sea- ling [533F], cover plate and nut [533G]. ...

  • Page 60: Mounting A Splice Table -60

    ALS 30x Installation Manual Mounting a splice table With the splice table option, the end of the preceding material roll can be taped to the beginning of the new roll. Thus, the material doesn´t have to be fed through the whole machine for each new material roll, what reduces the downtimes for material change.
  • Page 61 ALS 30x Installation Manual Mounting on an ALS 30x with on top unwinder Article number: A107827 Splice table with adapter plate [537] Splice table with adapter plate ready mounted. Mounting (RH machine):  Remove the on top unwinder [538]. The 4 screws are no longer used. [538] Removing the on top unwinder.
  • Page 62 ALS 30x Installation Manual  Lay a steel ruler [541C] alongside the surfaces [541A].  Align the unwinder foot laterally, until both surfaces [541A] are in the same plane.  Tighten the screws. Tightening torque: 45 Nm [541] Adjusting the unwinder´s zero line by aid of a steel ruler (C). 07/2024 | 01 Installation and Deinstallation...

  • Page 63: Mounting The Side Labeling Kit -63

    ALS 30x Installation Manual Mounting the side labeling kit For side labelling applications, mounting the additional stop disks contained in the kit is strongly recommend- ed. It prevents the label web from slipping laterally on the rollers. Article number: N100294 Tools: –...

  • Page 64: Mounting/Connecting The Signal Beacon -64

    Tighten the clamp screws [546B] at the guide rings. [546]Mounting the outer guide rings (A). Mounting/connecting the signal beacon NOVEXX Solutions offers a ready to use signal beacon for the ALS 30x. The LED lamps of the beacon show the colors red-yellow-green. The beacon can be con- nected to different signal interfaces, using the optional available cables.

  • Page 65: Decommissioning, Dismantling, Disposal -65

    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 66: Machine Disposal -66

    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 67: Function Menu -67

    ALS 30x Installation Manual Functions FUNCTION MENU Overview LABEL SETUP MACHINE SETUP (continued) INTERFACE PARA (continued) Load prod.profil Dispenser type Labelsen. InType >EASYPLUGINTERPR DHCP host name Gap detect. mode Store prod.prof. Startsen. In.Type Interface FTP server Dispense speed Del. prod.profil Start disp.
  • Page 68 ALS 30x Installation Manual SIGNAL INTERFACE (continued) SERVICE/DIAGNOS. SERVICE DATA (continued) Interface mode >AI BOARD SIGNAL Service >MODULE FW VERS. Work place >PLC SIGNALS Applicator type Serv. data reset System version Company name End dispense mod Apply mode Sensor Test System revision Disp.
  • Page 69 ALS 30x Installation Manual Notes on the description of functions The adjustment range or individual settings available for a function are shown in square brackets. – For functions with individual values for settings, the default value is printed in italics. –...
  • Page 70 ALS 30x Installation Manual Lab. stop offset function – Stopping position of the label at the dispensing plate – Adjustment range: [0.0…999.9] mm; default: 20.0 Start offset function The function has a different effect on slave machines in tandem operation. Standard operation or master machine: –...

  • Page 71: Machine Setup Menu -71

    ALS 30x Installation Manual Miss. label mode function – Determines the treatment of missing labels – Settings: [Compensate, Simulate] Compensate: Quick feeding with slew speed (see LABEL SETUP > Slew speed) until the next label arrives at the label sensor. A missing label will be passed with slew speed and the next label will be applied onto the product with a corresponding offset.
  • Page 72 ALS 30x Installation Manual Disp. Cnt. Reset function – Settings: [No, Yes] Yes: Dispense counter is set to zero. No: Dispense counter is not set to zero. Factory settings function – All functions are factory set to values depending on the relevant machine type. This factory set- ting can be reinstalled at any time.
  • Page 73 ALS 30x Installation Manual Sensor Adjust function – Adjusts the photoelectric sensors – Adjustment range: [0…100] %; default: 41 Speed Adaption function – Speed adjustment – Settings: [On, Off] On: The dispensing speed adapts automatically to match the speed of the conveyor belt. A ro- tary encoder must be installed in order to use this function.
  • Page 74 ALS 30x Installation Manual Tandem Operation function – Settings: [Off, Master, Slave, „FlipFlop master“] Off: Tandem Operation is disabled. Master: The first machine products on the conveyor belt reach. In classic master-slave mode, the slave machine replaces the master only for the short time, until an error at the master ma- chine is eliminated.
  • Page 75 ALS 30x Installation Manual Startsen. In.Type function – Product sensor input type – Settings: [NPN, PNP] Start disp. mode function – Defines either the rising or falling side of the start signal peak as the point when dispensing is triggered. –...
  • Page 76 ALS 30x Installation Manual – The function determines, how products are handled, which already had passed the start sensor, as the inhibit signal applied. The start signals triggered by the products are registered in a queue. – Settings: [„Do regist starts“, „Del regist strts“] „Do registered starts“: The queue is not touched.
  • Page 77 ALS 30x Installation Manual Mode Keycode User Supervisor Production [Tab. 98] Valid keycodes Mode Effect User Access to the LABEL SETUP and SERVICE DATA menus Supervisor Access to all functions except production functions (indicated in the overview) Production Access to all functions [Tab.

  • Page 78: Interface Para Menu -78

    ALS 30x Installation Manual  Press the key. Defines the diameter threshold for the material roll. If the (calculated) material roll diameter is below the threshold value, the following warning appears: ONLINE Material low Rewinder full function Defines the maximum permissible diameter of the wound backing paper on the backing paper rewinder.

  • Page 79: Submenu >Com1 Port -79

    ALS 30x Installation Manual CAUTION! To avoid malfunctions:  Do not send data to more than one interface at any one time. During tandem operation, Com1 is used for communication between master and slave machine. Therefore, the interface function may not be set to „Automatic“ or to „Serial Com 1“.

  • Page 80: Submenu >Network Param. -80

    ALS 30x Installation Manual – Settings: [Odd, Even, None, “Always zero”] Odd: Odd parity. A parity bit is added in such a way that the total number of 1 bits is odd. Even: Even parity. A parity bit is added in such a way that the total number of 1 bits is even. None: No check bit.
  • Page 81 ALS 30x Installation Manual Gateway address function  Enter address of the gateway in the form xxx.xxx.xxx.xxx – Possible range for each xxx value: [0…255] – 000.000.000.000 = no gateway address used Port address function – Adjustment range: [1024…65535]; default: 9100 Ethernet speed function –...
  • Page 82 ALS 30x Installation Manual WEB admin passw. function – Changes the admin password for the web server – default: “admin” – Access rights to functions are equivalent to those in supervisor mode (see MACHINE SETUP > Ac- cess authoriz.) WEB supervisor p. function –...
  • Page 83 ALS 30x Installation Manual Submenu >APPLIC. SIGNALS Only appears, if SIGNAL INTERFACE > Interface mode = „Applic. signals“. Applicator type function – If an applicator is used to attach the labels, the applicator type is set here. Alternatively, “Direct Dispense” should be selected to dispense without an applicator. –...
  • Page 84 ALS 30x Installation Manual Functions Applicators LTP - LTPV PEP Blow on PEP II Sensor Reverse PEP None (Direct Dispense) O-ring applicat. LA-BO LA-TO Timed LA-TO Sensor LA-TO BO Timed LA-TO BO Sensor [Tab. 100]The appearance of those menu functions depends on the selected applicator type (x = function appears). Status outputs function –...
  • Page 85 ALS 30x Installation Manual Blow on time function – Appears only if SIGNAL INTERFACE >APPLIC. SIGNALS > Applicator type = „PEP Blow on“, ASA, „Reverse PEP“, BTS, „O-ring applicat.“ or LA-BO – Sets the duration for blowing on of each label –...

  • Page 86: Signal Interface

    ALS 30x Installation Manual TouchDownTimeout function – Timeout at the touchdown sensor. This time specifies the maximal wait time for the touchdown trigger event. – Settings: [„Off“, (100...99999) ms“] Off: The function is switched off xxxx ms: If the specified time xxxx mx is exceeded without the touchdown event, the applicator continues operation in the same manner as the touchdown event would have taken place.

  • Page 87: Submenu >Ai Board Signal -87

    ALS 30x Installation Manual Touch down sens. function – See description of function SIGNAL INTERFACE >APPLIC. SIGNALS > Touch down sens. on Seite 1. TouchDownTimeout function SIGNAL INTERFACE >APPLIC. SIGNALS > TouchDownTimeout – See description of function on Seite 1. Submenu >AI BOARD SIGNAL SIGNAL INTERFACE This menu only appears, if an optional applicator interface (AI) is installed and if...

  • Page 88: Service/Diagnos. Menu -88

    ALS 30x Installation Manual SERVICE/DIAGNOS. menu Service function – Counter for service operations – Settings: [Yes, No] Yes: Increments the “Serv. operations” counter by one (see SERVICE DATA >OPERATION DATA > Service operations) No: Does not increment the counter. Serv. data reset function –...

  • Page 89: Service Data Menu -89

    ALS 30x Installation Manual Each of the file names is completed by the printer type and the serial number of the CPU board. The file content is english, regardless of the language setting at the printer. Those data are very helpful for the technical support for fault diagnosis purposes. Data blocks del.

  • Page 90: Submenu >Operation Data -90

    ALS 30x Installation Manual uMon function – Shows the micromonitor version number. – Only for factory-internal purpose. Applicator int. function – Shows the firmware version of the applicator interface: Applicator int. V 1 – T 17 V1 – T17 means firmware version 1.17. Submenu >OPERATION DATA Service operations function –...

  • Page 91: Submenu >Cpu Board Data -91

    ALS 30x Installation Manual Submenu >CPU BOARD DATA CPU identifier function – Displays the identification of the processor used PCB Revision function – Displays the layout revision und part number of the CPU board FPGA version function – Displays the FPGA version MAC Address function –...

  • Page 92: Submenu > Peripheral Data -92

    ALS 30x Installation Manual Submenu > PERIPHERAL DATA Applicator int. function – Function only appears when there is an applicator interface installed – Shows the PCI model of the applicator interface Submenu >MEMORY DATA RAM memory size function – Shows the size of the available RAM Flash mem size function –...

  • Page 93: Operation -93

    ALS 30x Installation Manual Operation AUTOMATIC DISPENSING SPEED ADJUSTMENT Principle of operation The automatic dispensing speed adjustment (APSF) doesn´t work, if the labeler is equipped with a pneumatic dispensing edge. [548]Rotary encoder (A) on the conveyor line (schematic) The automatic dispensing speed adjustment makes it possible to automatically adapt the dispens- ing speed to the speed of the conveyor belt.

  • Page 94: Mounting The Rotary Encoder -94

    ALS 30x Installation Manual Mounting the rotary encoder Rotary encoder with measuring wheel at the conveyor belt A measuring wheel translates the conveyor belt movement into rotation of the rotary encoder shaft. Diameter of the measuring wheel [549D] and resolution (impulses per rotation) of the rotary encod- er can be entered directly in the function menu.

  • Page 95: Entering The Rotary Encoder Resolution -95

    ALS 30x Installation Manual [551] Mounting the rotary encoder on the motor axle. Entering the rotary encoder resolution Call the function MACHINE SETUP > Encoder Resol.   Enter the resolution of the rotary encoder to be used. – Adjustment range: [0.0…9999] pulses/revolution –...

  • Page 96: Example: Entering The Values For The Recommended Rotary Encoder -96

    ALS 30x Installation Manual Single-phase operation Only one phase of the encoder signal (signal A) is utilized. Advantage: – less expense (as with double-phase) Disadvantage: – Lower resolution (as with double-phase) – If the conveyor is standing still, vibrations can produce „faulty“ signals, which the labeler cannot distinguish from „real“...
  • Page 97 ALS 30x Installation Manual yy.y = belt speed according to current measurement var = indicates variable belt speed If the actual belt speed is known, the measured speed can be synchronised with it as follows:  Increase or decrease the diameter of the measuring wheel until the belt speed displayed match- es the actual speed.

  • Page 98: Tandem Operation -98

    ALS 30x Installation Manual TANDEM OPERATION [553]Two labelers in tandem arrangement: A Master (in the illustration: currently active, but with a label roll that is running low) B Slave (in the illustration: in standby, with a full label roll) Overview In tandem operation, two labelers are arranged one behind the other.

  • Page 99: Prerequisites -99

    ALS 30x Installation Manual Prerequisites – Hardware: Two labelers, both RH or both LH, one mounted directly behind the other on the con- veyor line. Both machines must be equipped with the same electronics generation (both „Gen. 1“ or both SERVICE DATA >CPU „Gen.
  • Page 100 ALS 30x Installation Manual Plug Coupling Plug to machine Plug to machine (male) (male) 1 brown Plug 2 white brown 1 3 blue Signal B white 2 4 black blue 3 Signal A black 4 1 brown 2 white 3 blue 4 black Binder Series 713 99-1429-812-04...

  • Page 101: Setting Up Tandem Operation -101

    ALS 30x Installation Manual Setting up tandem operation Connecting the machines use half of AK3233 (Reichelt Elektronik) yellow brown metal cover metal cover Lötseite Steckseite metallized metallized plastic plastic cover cover blue blue yellow green CN2A CN1A brown white green yellow white brown...
  • Page 102 ALS 30x Installation Manual [556] Connections for the tandem interface cable (A, B). If both machines are connected to a network, standard (1:1) network cables are required for connection. 07/2024 | 00 Operation...
  • Page 103 ALS 30x Installation Manual Settings in the functions menu - syncronisation via Com1 From firmware version 2.52 on, the appropriate settings for both COM1 ports are done automati- (MACHINE SETUP > Tandem synchron.. = „Serial cally, if COM1 is selected as communication port Com1“).
  • Page 104 ALS 30x Installation Manual Settings in the functions menu - syncronisation via Ethernet interface Table 102 contains example addresses for a direct connection (peer-to-peer) of the machines. For connection to a network, the addresses have to be provided by the network administrator.
  • Page 105 ALS 30x Installation Manual Optional Settings The following settings affect tandem operation regardless of the selected synchronisation type. Setting at: Menu > Submenu Function Setting MACHINE SETUP > Tandem startmode Master and Slave „1 Start sensor“ or „2 Start sensors“ (higher dis- pensing accuracy with 2 sensors, especially with large distance between master and slave) Master...
  • Page 106 ALS 30x Installation Manual Display on master – Master mode: Online Master Labels – Flipflop master mode: Online FF-Master Labels – The machine is ready for operation and begins labelling once it receives a signal from the prod- uct sensor. Display on slave Online Slave Dispenser locked...
  • Page 107 ALS 30x Installation Manual CAUTION! Machine stoppage in case of material end at the slave, while the master is stopped.  Ensure sufficient material supply at the slave  MACHINE SETUP > Materialend warn Activate material warning at the slave, see MACHINE SETUP >...
  • Page 108 ALS 30x Installation Manual Status Master Slave Material end at slave, Online FF-Master Status num: 5002 master starts labelling. Labels Material end Acknowledge error: Press the button Replenish material Master is labelling Online FF-Master Online Slave Labels Dispenser locked [Tab. 105]Master and slave displays during material change. 07/2024 | 00 Operation...
  • Page 109 ALS 30x Installation Manual Toggling to master already after material warning: If the function „material warning“ is activated at the slave, it toggles back to the master as soon as MACHINE SETUP a material warning occurs, what means that a preset roll diameter is reached (see >...

  • Page 110: Function -110

    ALS 30x Installation Manual APPLICATOR OPERATION Function In order to match applications, which do not allow direct labelling from the dispensing edge onto the product, the labeler can be equipped with an applicator. The applicator bridges a certain distance between dispensing edge and product. In applicator operation, the applicator takes the label over from the dispensing edge and transfers it to the product.
  • Page 111 H Click on this button after entering user name and password Displays the machine model J Displays the firmware version K Links to the NOVEXX Solutions website L DHCP host name (see INTERFACE PARA >NETWORK PARAM. > DHCP host name)
  • Page 112 ALS 30x Installation Manual Applications The web server makes it possible – to set or read the values of functions from the function menu via a web browser – to control the operator panel of the labeler via a web browser. The web server is not multi-session compatible, i.e.
  • Page 113 ALS 30x Installation Manual Startfehler Halt [562] Example: Dialog box for entering value for the function MACHINE SETUP > Some functions trigger a reset of the labeler, if they have been changed on the labeler via the operator panel. However, if any of these functions is changed via the web server, the reset does not occur automatically.
  • Page 114 ALS 30x Installation Manual The virtual operator panel [564] The virtual operator panel After the “Display view” link is clicked, an image of the labeler operator panel (= virtual operator pan- el) appears on the screen [?]. All of the buttons on the real operator panel can also be operated by mouse-click on the virtual operator panel.
  • Page 115 ALS 30x Installation Manual FTP server Applications The file transfer protocol (FTP) server (RFC959) enables access to the labeler's internal RAM disk and to the compact flash card in the card slot of the labeler (as long as there is a compact flash card in the slot).
  • Page 116 ALS 30x Installation Manual [566] Folders on the USB stick (A). [567] Files in folder „SupportData“. If the login was successful, separate folders appear in the FTP client, one for the internal RAM disk and one for each connected memory medium [?]: –...
  • Page 117 ALS 30x Installation Manual SAVING/LOADING A CONFIGURATION Applications It sometimes happens that all of the parameter settings for a labeler must be restored or transferred to another labeler. In such cases, the user can import all of the function settings together as a set, saving time, money and stress.
  • Page 118 ALS 30x Installation Manual File name and directory can be changed using buttons on labeler operator panel. If a file with the name entered already exists, this will be overwritten without asking for confirma- tion. Loading from an external memory medium Selecting a file ...
  • Page 119 ALS 30x Installation Manual Automatic loading  Save the configuration file as \AUTOSETUP.FOR (in the memory medium root directory) Importing the settings:  Switch labeler off  Insert memory card  Switch labeler on The import of the function settings starts automatically. Display after settings have successfully been applied: Switch off Remove card...
  • Page 120 ALS 30x Installation Manual Some tips about transfer via a USB or Ethernet interface: – The procedure described does not work with Windows 98, Windows ME or Windows NT 4.0. – The Share name must satisfy MS-DOS conventions (max. 8 characters length, no spe- cial characters or spaces) Example of a printout from SETUPALL.FOR #!A1...
  • Page 121 ALS 30x Installation Manual #PC1103/1 #G *Dispenser ID no. : 1 #PC1104/64 Spooler size 64 KBytes #PC2072/0 Offline mode : Interf. disabled #PC2021/0 Interface delay 0 ms #G----------------------------------------------------------------------------- #G COM1 Port Parameter #G----------------------------------------------------------------------------- #PC1201/8 Baud rate : 115200 Baud #PC1202/8 No.
  • Page 122 ALS 30x Installation Manual #PC5133/0 #G *Loop dancer val. : 0 #G----------------------------------------------------------------------------- #G DHCP Addresses #G----------------------------------------------------------------------------- #G readonly ID=30001 IP address : 144.093.029.047 #G readonly ID=30002 Net mask : 255.255.254.000 #G readonly ID=30003 Gateway address : 144.093.028.001 #G----------------------------------------------------------------------------- #G Module Firmware Versions #G----------------------------------------------------------------------------- #G readonly ID=30004...
  • Page 123 ALS 30x Installation Manual #PC5124/0 Debug mask #PC5128/-1872945986 Debug IP address : 144.093.028.190 #PC5404/0 Fields : Off #PC5400/0 Label generation : Off #PC5401/0 Print handling : Off #PC5402/0 Variables : Off #PC5408/0 OLV data : Off #PC5403/0 Pctrl communica. : Off #PC5406/0 RFID-Reader : Off...
  • Page 124 ALS 30x Installation Manual SIGNAL INTERFACE General notes The signal interface is a D-Sub15 (fem.) connector [569A]. Furthermore, the machine is equipped with separate M12 sockets for inputs and outputs [569B,C]. The signal interface can be used as interface for applicator signals or for PLC signals. The selection of the interface type is done via the function menu: SIGNAL INTERFACE >...
  • Page 125 ALS 30x Installation Manual Circuit diagrams for signal inputs +24 V PLC_IN_A Sensor PLC_IN_K Masse [570] Main circuit for signal inputs (NPN) +24 V Sensor PLC_IN_A PLC_IN_K Masse [571] Main circuit for signal inputs (PNP) 07/2024 | 02 Electronics Description...
  • Page 126 ALS 30x Installation Manual Circuit diagram for signal outputs +24V [572] Main circuit for signal outputs. Signals for applicator connection SIGNAL INTERFACE > Interface mode Required setting: = „Applicator int.“. Home A Home K Touch Down A Touch Down K n.
  • Page 127 ALS 30x Installation Manual Signal name Function Home Input Active, if the applicator has reached the home position (application is finished) Touch Down Input Use with sensor-controlled applicators (e. g. LTP) Active, if the applicator touches the product Cylinder Output Controls the pneumatic cylinder of the applicator Active during the dwell time or until touch down SIGNAL INTERFACE >APPLIC.
  • Page 128 ALS 30x Installation Manual Applicator type <--> Signals The table below lists all the signals that are required by the relevant applicator type to be able to work. With some applicator type settings, the interface provides additional signals, which are not mandatory for the applicator to work, e.
  • Page 129 ALS 30x Installation Manual Signal wave forms of applicator signals For details about applicator types read the description of function SIGNAL INTERFACE >APPLIC. SIGNALS > Applicator type on page 80. Start signal Home position Airstream support Cylinder (setable) Additional signals available with optional Applicator Interface: Offline Cycle Inhibit...
  • Page 130 ALS 30x Installation Manual PEP Blow On, LA-TO BO timed Start signal Home position Airstream support Cylinder (setable) Vacuum Blow on (setable) Additional signals available with optional Applicator Interface: Offline Cycle Inhibit Applicator type [109] Pattern of control signals over time for the settings = „PEP Blow on“...
  • Page 131 ALS 30x Installation Manual Reverse PEP Start signal Home position Airstream support Cylinder (setable) Vacuum Blow on (setable) Additional signals available with optional Applicator Interface: Offline Cycle Inhibit [110] Pattern of control signals over time for the setting Applicator type = „Reverse PEP“.
  • Page 132 ALS 30x Installation Manual LTP, LTPV, LA-TO BO sensor The blow on signal is provided by the interface, even though it is not required by this applicator type. Start signal Home position Airstream support Cylinder (setable) Vacuum Touch down Blow on (setable) Additional signals with optional Applicator Interface: Offline...
  • Page 133 ALS 30x Installation Manual PEP II Sensor Start signal Home position Airstream support Cylinder (setable) Vacuum Touch down Blow on (setable) Additional signals with optional Applicator Interface: Offline Cycle Inhibit [112] Pattern of control signals over time for the settings Applicator type = „PEP II Sensor“.
  • Page 134 ALS 30x Installation Manual LA-TO sensor Start signal Home position Airstream support Cylinder (setable) Vacuum Touch down Additional signals with optional Applicator Interface: Offline Cycle Inhibit Applicator type [113] Pattern of control signals over time for the setting = „LA-TO Sensor“. A Duration is determined by label length and dispensing speed.
  • Page 135 ALS 30x Installation Manual LA-TO timed Start signal Home position Airstream support Cylinder (setable) Vacuum Additional signals available with optional Applicator Interface: Offline Cycle Inhibit Applicator type [114] Pattern of control signals over time for the setting = „LA-TO zeitgest.“. A Duration is determined by label length and dispensing speed.
  • Page 136 ALS 30x Installation Manual The ASA is a special case, which does not have any moving parts. The label is applied only by com- pressed air. Therefore, signals controlling the movement of the applicator (Home position, Cylinder) are not required. Start signal Airstream support...
  • Page 137 ALS 30x Installation Manual LA-BO Start signal Airstream support Blow on (setable) Additional signals available with optional Applicator Interface: Offline Cycle Inhibit Applicator type [116] Pattern of control signals over time for the setting = „LA-BO“. A Duration is determined by the label length and dispensing speed. „Airstream Support“ switching to low means the label is dispensed.
  • Page 138 ALS 30x Installation Manual Signals for PLC connection Required setting: SIGNAL INTERFACE > Interface mode = „PLC signals“. Inhibit A Inhibit K Warning In A Warning In K Error In A Error In K +24 V Error Ready Dispense End Warning [576] Pin assignment D-Sub15 connector 5 GND...
  • Page 139 ALS 30x Installation Manual Signal name Function Ready Output Active in dispensing mode (online or online settings) Not active in configuration mode (offline inclusive error status) and in tandem mode at the deactivated machine < 500 mA Error Output Signal active when an error message appears on the operator panel display <...
  • Page 140 ALS 30x Installation Manual – Modes high/low pulse: The signal is activated after dispensing ended and after period B and it lasts period C [579C]. 07/2024 | 02 Electronics Description...
  • Page 141 ALS 30x Installation Manual Impact of the inhibit signal The description in this chapter only affects the inhibit input at the standard signal interface (in PLC mode), not the inhibit input at the optional applicator interface. MACHINE SETUP > On inhibit enter The impact of the inhibit signal on the start signal is influenced by MACHINE SETUP >...
  • Page 142 ALS 30x Installation Manual Dispensing edge = Product will not be labelled Product sensor = Product will be labelled Start signal Inhibit signal [581] Example of setting combination A1B2. Green arrow: the rising slope causes products registered in the queue to be labelled.
  • Page 143 ALS 30x Installation Manual Dispensing edge = Product will not be labelled Product sensor = Product will be labelled Start signal Inhibit signal [583] Example of setting combination A2B2. 07/2024 | 02 Electronics Description...
  • Page 144 ALS 30x Installation Manual DATA INTERFACES RS 232 Signal 1, 4, 6 connected Ground not used [Tab. 117]Pin assignment for RS 232 interface (looked at from „PC point of view“; Dispenser = DCE) Suitable connection cable to a PC: – D-Sub9, 1:1, connector-socket (extension cable) –...
  • Page 145 ALS 30x Installation Manual USB (host) Only with Gen. 2 CPU board. Pin Signal Data- Data+ [Tab. 119]Pinout USB interface Ethernet Signal 1 TD + 3 TD – 2 RD + Termination Termination 4 RD - Termination Termination [Tab. 120]Pin assignment for Ethernet interface A Connection at standard device (RJ 45) B Connection at device with splash/dust guard (M12 [585]...
  • Page 146 ALS 30x Installation Manual IP address: The labeller firmware implements a TCP/IP protocol stack, which means that the labeller needs an IP address for the network in addition to its MAC address. IP addresses are always written in decimal format as 4 bytes separated by points (e.g.
  • Page 148 Novexx Solutions GmbH Ohmstraße 3 85386 Eching Germany  +49-8165-925-0 www.novexx.com...

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