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Novexx Solutions ALS 306 User Manual

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USER MANUAL
ALS 30x
Labeler
Edition 5 - 11/2024 - Translation of original version

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Summary of Contents for Novexx Solutions ALS 306

  • Page 1 USER MANUAL ALS 30x Labeler Edition 5 - 11/2024 - Translation of original version...
  • Page 3 ALS 30x User Manual Contents Please note General notes Validity and binding effect of this manual Illustrations and descriptions Safety instructions Information and qualifications Operational safety of the unit Warning notes on the unit Product description Overview Components Control panel Connection arrangement Mode of operation Design models...
  • Page 4 ALS 30x User Manual Applicator Applicator interface Side labelling kit Narrow label spring kit Signal beacon Operating modes Dispensing mode Configuration mode Function descriptions Overview of functions Notes LABEL SETUP menu MACHINE SETUP menu Before operation Electrical connections Power supply connection Connecting sensors Inserting label material Prerequisites...
  • Page 5 ALS 30x User Manual Operational failures Status messages Types of status messages List of warnings List of error messages EU Declarations EU Declaration of Conformity EU Declaration of Incorporation Appendix regarding the Declaration of Incorporation 11/2024 Contents...
  • Page 6 ALS 30x User Manual 11/2024 Contents...
  • Page 7 Technical state: 5/2019 Software version: 2.76 Liability NOVEXX Solutions reserves the right: – To make modifications to construction parts, components and software, as well as to employ comparable components in place of the parts specified, in keeping with technical advances.
  • Page 8 ALS 20x/256 Service Manual Copyright NOVEXX Solutions holds all rights to this manual and its appendices. Reproduction, reprinting or any other types of duplication, even of portions of this manual, may only be carried out with express written consent. Manufacturer...
  • Page 9 ALS 20x/256 Service Manual Button symbols – The buttons of the control panel are depicted as symbols. – The symbols are depicted with a ‘+’ (PLUS SIGN) between them if more than one button is to be pressed. Functions Functions are displayed in grey in the text with the following structure, MENU NAME >...
  • Page 10 ALS 30x User Manual SAFETY INSTRUCTIONS Information and qualifications Ensure the required qualifications are met  Ensure that only trained and authorized personnel operate, configure and service the unit.  Only allow qualified and well-trained expert personnel or service technicians to perform config- urations.
  • Page 11 ALS 30x User Manual 1) For example faults when detecting labels 2) For example incorrect labelling Follow the instructions WARNING! Safe and efficient operation of the labeler can only be guaranteed if you observe all necessary information.  Before operating the unit, read the operating instructions and all other notes carefully. Observe the additional safety and warning notes on the labeler.
  • Page 12 ALS 30x User Manual Protection against injuries by electrical current WARNING! The machine operates using mains voltage! Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns.  Only operate the unit once the housing has been reassembled properly. The machine may only be connected by authorised specialists, who are aware of the risks ...
  • Page 13 ALS 30x User Manual Crushing hazard on the dispensing edge due to products on the conveyor equipment!  Never reach between the product and the dispensing edge while the unit is in operation or ready for operation.  Never reach behind the safety guard or remove it while the unit is in operation. Tripping hazard! ...
  • Page 14 ALS 30x User Manual Warning notes on the unit CAUTION! Warning notes on the unit represent important information for the personnel using it.  Do not remove warning notes.  Replace any missing or illegible warnings. [1] Position of the warning notes on the machine. Warning note Meaning Article no.
  • Page 15 ALS 30x User Manual Product description OVERVIEW Components [2] ALS 306 Labeler (right-handed version). 11/2024 | 01 Product description...
  • Page 16 ALS 30x User Manual A Dancer arm – Keeps the label material stretched tight evenly. – Brakes the rotation of the material roll if tension diminishes. B Unwinder – Spread core mandrel grasps the label roll. C Core diameter adapter –...
  • Page 17 ALS 30x User Manual Control panel STATUS Online Labels – – [3] The ALS 30x control panel (in dispensing mode) A Operating LED B Error LED C LCD display D Buttons Operating LED Lights up green when the device is switched on. Error LED Lights up red when an error occurs.
  • Page 18 ALS 30x User Manual Connection arrangement Connections on the rear side of the device [4] Connections on the machine rear side. A Label sensor B Product (start) sensor C Rotary encoder (for automatic speed adaption) D Alternative label sensor E Roll diameter sensor (for external OD-control on unwinder 1 or 2) F Signal inputs (optional) G Signal outputs (optional) H not applied...
  • Page 19 ALS 30x User Manual O Memory card slot (SD/MC cards) P Connection for external control panel (RS485) Q Serial interface (RS232) R Network connection (Ethernet 10/100) S Optional: Applicator Interface (AI) T Power supply connection U USB-A (host) interface (USB stick) For information on connecting the unit see chapter Power supply connection ...
  • Page 20 ALS 30x User Manual Mode of operation In labelling mode, the label web is first pulled from the label roll around the dancer arm [5A], which consistently maintains even tension in the label web. The feed rollers [5D] in front of and behind the dispensing edge [5C] draw the label web across the dispensing plate.
  • Page 21 ALS 30x User Manual Design models The ALS 30x can be adapted to client requirements under several aspects: Aspect Adaption Conveyor direction Right-handed (RH) / Left-handed (LH) machine Mounting position of the machine Horizontal / vertical Top / side labelling Mounting point at the machine Top / bottom / right / left / rear side Unwinder amount...
  • Page 22 ALS 30x User Manual [7] ALS 30X (LH) with the following features: Conveyor direction = from right to left Mounting position = horizontal / top labelling Unwinder amount = 2 Unwinder mounting point = lateral left and right [8] ALS 30X (RH) with the following features: Conveyor direction = from left to right Mounting position = vertical / side labelling Unwinder amount = 1...
  • Page 23 ALS 30x User Manual TECHNICAL SPECIFICATIONS Characteristics Dispensing speed ALS 306 max. 60 m/min ALS 309 max. 45 m/min Labelling halt precision at the peeling edge: Variable speed: < ±1 mm Constant speed: < ±0.5 mm Speed control: Fixed setting or automatic speed adaption...
  • Page 24 ALS 30x User Manual Power supply System voltage: 100-240 V (AC) at 60/50 Hz power frequency (permissible tolerance ±10%) Current consumption: max. 5.1 A at 100 V max. 2.1 A at 240 V Power consumption: max. 510 VA Fuses: Fuses integrated in the power supply 4) Not accessible for user or service technician.
  • Page 25 Operating hours counter Storage locations for product profiles: up to 16 Dimensions Width x height x depth: ALS 306 726 x 389 x 386 mm 726 x 802 x 386 mm ALS 309 726 x 389 x 470 mm 726 x 802 x 470 mm...
  • Page 26 ALS 30x User Manual Ambient conditions Installation location: Inside buildings Protected from wind and spray water Not in areas with potentially explosive atmos- phere Operating temperature: 5 to 40°C Humidity: 30 to 85%, (non-condensing) Noise (at a distance of 1 m): 72 dB(A) Protection class: IP 21...
  • Page 27 ALS 30x User Manual OPTIONS External control panel – An external control panel can be connected in addi- tion to the integrated control panel. – An external control panel is useful if the standard control panel is difficult to access due to the position in which the unit is installed.
  • Page 28 ALS 30x User Manual Pneumatic dispensing edge – The dispensing edge is pivoted in the dispensing head. Compressed air presses the dispensing edge onto the surface of the product. – Allows compensation for height differences be- tween the products or on the product surface. [13] Pneumatic dispensing edge Euro dispensing edge holder Enables a vertical fine adjustment of the dispensing...
  • Page 29 Particular- ly effective is the use of a splice table and two material unwinders [16]. [16] ALS 306 with splice table Dust/Splash guard Additional sealing of the electrical connections and of the housing fulfils the requirements of the IP 54 protec- tion class [17].
  • Page 30 ALS 30x User Manual Cable kit for internal outer diameter control Those cables are required to connect the sensors, which are integrated in the unwinder, to the control unit of the ALS 30x. If connected, the internal OD-control can be used. For 2 unwinders, 2 cable kits are required. [19] Cable kit for internal outer diameter control Additional material guide disk The additional material guide disk [20A] improves the...
  • Page 31 ALS 30x User Manual Printer If necessary, you can mount a hot stamp printer (not available from Novexx Solutions) onto the holder rods of the dispensing edge. Example of use: Printing consecutive numbers onto labels. Applicator If it is not possible to label directly from the dispensing edge, you can fit an applicator to the labeler.
  • Page 32 ALS 30x User Manual OPERATING MODES Dispensing mode This is the operating mode of the unit when switched on. You can carry out the functions listed in the sections STATUS below. Online If text such as ‘Prof 5 xxxxxxxx’ is displayed Labels instead of ‘ONLINE’: –...
  • Page 33 ALS 30x User Manual Online settings The machine is in dispensing mode. To switch to the online settings mode: STATUS  Press the button. – The display shows the dispensing speed [25A] and Speed Offset 12.2 fix 15.0 the start offset [25C]. –...
  • Page 34 ALS 30x User Manual Configuration mode The machine is in dispensing mode. Switching to configuration mode: STATUS  Press the button twice. – Display: OFFLINE OFFLINE – –  Press the button. – Display: LABEL SETUP – LABEL SETUP is the name of the first menu that is LABEL SETUP currently active.
  • Page 35 ALS 30x User Manual Functions Every submenu contains functions for setting the unit controls. Figure [27] shows the button functions for changing set- MACHINE SETUP > Language tings using the function as an example (English is the preset language, so you most probably don´t have to change this setting.
  • Page 36 ALS 30x User Manual FUNCTION DESCRIPTIONS Overview of functions 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 37 ALS 30x User 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 38 Autom. forward: The material initialization is always done automatically, if necessary. Dispense speed function – The speed at which the label is dispensed – Setting range: ALS 306: [1.0…60.0] m/min; default: 10.0 ALS 309: [1.0…45.0] m/min; default: 10.0 – See Dispensing speed ...
  • Page 39 – Feed speed at which the label material is driven if missing-label-gaps occur and during the au- tomatic measuring of the label length – Setting range: ALS 306: [1.0…60.0] m/min; default: 1.0 ALS 309: [1.0…45.0] m/min; default: 1.0 Label pitch function –...
  • Page 40 ALS 30x User Manual Label 3 offset function – Only appears if LABEL SETUP > Multi label mode = „3 labels/start“. LABEL SETUP > Multi label mode – Defines the distance of the 3rd label for the function (see above). The distance is measured from the front label edge of the preceding label.
  • Page 41 ALS 30x User Manual Language function – Language of display text – Settings: [German, English, French, Spanish, Dutch, Danish, Italian, Polish, Turkish, Russian] Materialend err function – Refers to the internal OD control. – Settings: [Off, „Mat.diam < x mm“] –...
  • Page 42 ALS 30x User Manual – Setting range: [50…500] mm; Default setting: 270 mm 11/2024 | 00 Product description...
  • Page 43 ALS 30x User Manual Before operation ELECTRICAL CONNECTIONS Power supply connection WARNING! This machine operates using mains volt- age! Touching live electrical parts may expose you to hazardous electrical cur- rents and may lead to burns.  Make sure that the machine is switched off before you connect the pow- er cable.
  • Page 44 ALS 30x User Manual Disconnecting the power cable  Make sure that the power switch [30A] is set to ‘O’ (off).  Open the locking clip [30B] .  Pull the connector off. [30] Locking clip (B) closed. 11/2024 | 00 Before operation...
  • Page 45 ALS 30x User Manual Connecting sensors WARNING! The machine operates using mains volt- age! Touching live electrical parts may expose you to hazardous electrical cur- rents and may lead to burns. Only link the unit to devices that fulfil  the SELV (safety extra-low voltage) cir- cuit requirements specified in EN 60950.
  • Page 46 ALS 30x User Manual INSERTING LABEL MATERIAL Prerequisites – The labeler is turned off at the main switch [33A] (switch set to ‘O’).  Check that the safety installations are working properly. Inspect the machinery for any visible damage. Re- ...
  • Page 47 ALS 30x User Manual Inserting a label roll WARNING! Risk of injury due to moving and rapidly rotating parts!  Before inserting the label roll, ensure that the device is in offline mode. Danger of injury caused by falling label roll! ...
  • Page 48 ALS 30x User Manual Threading diagrams [36] Threading guide for ALS 30x (dotted line = roll with labels facing inwards). 11/2024 | 01 Before operation...
  • Page 49 ALS 30x User Manual [37] Threading guide for ALS 30x with a 45° rotated dispensing edge (dotted line = roll with labels facing inwards). 11/2024 | 01 Before operation...
  • Page 50 ALS 30x User Manual [38] Threading guide for ALS 30x with a 90° rotated dispensing edge (dotted line = roll with labels facing inwards). For use with a swivelling angle of 30° or more, additional deviation rollers must be installed: –...
  • Page 51 ALS 30x User Manual Threading the label web at the dispensing edge Fixed [39] and swivelling L-shape dispensing edges: Unroll 2.5 m of label web and remove the labels from   Pass the backing paper around the first deflection roller [39A] and through the slot in the sensor [39B].
  • Page 52 ALS 30x User Manual Threading the label web onto the drive roller  Open the pressure roller. To do so, rotate the lever [42A] in a clockwise direction.  Feed the backing paper around the deflection rollers [42B] and the drive roller [42C]. ...
  • Page 53 ALS 30x User Manual Threading the label web to the rewinder  Feed the backing paper around the deflection rollers and the dancer arm as illustrated [44].  Clamp the backing paper to the rewinder as shown and tighten it [44][45]. If the machine is switched off: Manually rotate the rewinder by one turn.
  • Page 54 ALS 30x User Manual MECHANICAL SETTINGS Adjusting the unwinder’s core diameter Tool: – 3 mm hexagon (Allen) screwdriver The unwinder can be adjusted with core adapters [46A] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depend- ing on this diameter: –...
  • Page 55 ALS 30x User Manual Positioning the label sensor  Release the thumb screw.  Position the sensor along the axle in such a way as to allow it to register the spaces between the labels. The LEDs [49A] light up when the sensor is positioned over a gap.
  • Page 56 ALS 30x User Manual Operation START-UP AND SHUTDOWN Turning on the unit [52] Main switch (A) of the ALS 30x.  Set the main switch [52A] of the unit to ‘I’ (On). – The following messages are displayed during the start process: ALS306 RH V 2.75 (machine type and firmware version)
  • Page 57 ALS 30x User Manual  Press the button. – The machine is in configuration mode: Press the button briefly (less than two seconds).  Stopping/Continuing the dispensing process – The machine is in dispensing mode. Stopping the dispensing:  Press the button.
  • Page 58 Lab. stop offset  At maximum dispensing speed set the to at least the following value ALS 306: 10 mm ALS 309: 7 mm  Lab. stop offset LABEL SETUP > Label pitch Don´t set to the same value as (also not to a multiple of the value).
  • Page 59 ALS 30x User Manual The next label to be dispensed waits in the label stop position. Here it is useful if the label protrudes over the dispensing edge a little [54]. The labeler was pre-configured ex works for use with the supplied label sensor. If this sen- sor is used, the label stop position setting will only require minimal correction.
  • Page 60 ALS 30x User Manual the product passes the dispensing edge, those signals can be suppressed by setting function LABEL SETUP > Product length to the product length. Example [55]: If the product [D] reaches the product sensor [C], a start signal is sent and the machine dispenses a label.
  • Page 61 ALS 30x User Manual [56] Distance between the product sensor (left) and the dispensing edge (right). [57] Distance (A) between the label and the product’s front edge. Monitoring functions While in dispensing mode, an electronic controller monitors the following functions: Material end / Roll diameter (OD = outer diameter) To enable a quick renewal of the material roll, the machine can alarm the operator before the end...
  • Page 62 ALS 30x User Manual Material end Critical OD reached Error message Warning Error message No OD-control Status num: 5001 none none No gap found Internal OD-control Status num: 5072 ONLINE Status num: 5071 Material end unw Material low Material end unw External OD-control none ONLINE...
  • Page 63 ALS 30x User Manual – Material is torn between feed roller and rewinder [58C]: Status num: 5140 Rewinder control See chap. Operational failures  on page 70. [58] Material tear off in sections A, B or C leads to different error messages. Rewinder full If the diameter of the rewound backing paper [59A] exceeds the admissible diameter (270 mm), the following message appears:...
  • Page 64 ALS 30x User Manual USING PRODUCT PROFILES What are product profiles? Product profiles are memory locations that can store all the settings for the machine controls. For recurring production jobs, they allow you to quickly set the machine to the respective product. –...
  • Page 65 ALS 30x User Manual Storing a product profile Selecting the memory location MACHINE SETUP > Store prod.prof.  Call the function. – Display shown when all memory locations are unoccupied: Store prod.prof. Prof 1 Product 1 – When memory locations are already occupied, the memory location that was last active is dis- played: Store prod.prof.
  • Page 66 ALS 30x User Manual Deleting a product profile  Call the MACHINE SETUP > Del. prod.profil function. – The memory location that was active last is displayed.  Press the or the button until you retrieve the memory location you require (1–16). ...
  • Page 67 ALS 30x User Manual After operation MAINTENANCE AND CLEANING Cleaning agents CAUTION! Unsuitable cleaning agents can cause considerable damage to the unit!  Do not use any cleaning agent that could damage or destroy the resin surface, la- belling, display, nameplates, electrical components, etc. Observe the instructions of the cleaning agent manufacturer.
  • Page 68 ALS 30x User Manual Regular maintenance The labeler is designed to be maintenance-free. However, you should service the unit regularly in order to ensure reliable long-term operating results. Removing paper debris Depending on operating conditions, you should perform the following at least once a week: ...
  • Page 69 ALS 30x User Manual [62] Filter liner (A). 11/2024 | 00 After operation...
  • Page 70 ALS 30x User Manual Operational failures STATUS MESSAGES Types of status messages Error messages When an error occurs, the machine stops immediately and displays an error message on the con- trol panel. Error messages are displayed as follows: Status num: 5144 Rewinder init [63] An example of an error message:...
  • Page 71 ALS 30x User Manual List of warnings Displayed text Meaning Productstartwarn New start signal during the dispensing operation. Several missing labels on the web, which can not be compensated. APSF speed warn. The conveyor speed exceeded the max. speed of the dispenser. OD sensor warn.
  • Page 72 ALS 30x User Manual List of error messages Status Status text Cause Action to take 5000 Bus device Device at I C Bus cannot be contact- Delete the message by pressing the -key. In most cases, this message appears Switch the machine off, wait 30 sec- as the first in a series of two or three onds and switch it back on.
  • Page 73 ALS 30x User Manual Status Status text Cause Action to take 5072 Material end unw Occurs during operation with activated Check the material feeding; if neces- internal OD control. sary, replenish the material roll. The message appears, if no rotation of the mate-rial roll has been registered during at least 600 mm of material feeding.
  • Page 74 ALS 30x User Manual Status Status text Cause Action to take 5147 Tandemsynch.init This message can only appear Check, if the slave machine had been during tandem operation. switched on before the master ma- chine - if not, repeat the switching on in the correct order (first slave, then mas- Communication between the master ter).
  • Page 75 ALS 30x User Manual Status Status text Cause Action to take 9022 No network link This status message can only appear Check whether the network connector when Ethernet address assignment is is plugged in correctly, correct if nec- set to DHCP (INTERFACE PARA >NET- essary.
  • Page 76 Germany hereby declare that we have designed and built the machine designated below so that it is in conformity with the basic safety and health protection requirements of the directive named below: ALS 306 / ALS 309 Models Labeler General designation...
  • Page 77 The designated partly completed machine must not be placed in operation until it has been determined that the machine in which the partly completed machine has been installed is in compliance with the provisions of direc- tive 2006/42/EG. ALS 306 / ALS 309 Models Labeler...
  • Page 78 ALS 30x User Manual APPENDIX REGARDING THE DECLARATION OF INCOR- PORATION List of the essential health and safety requirements applied and fulfilled for the product named in the declaration of incorporation, relating to the design and construction of machinery. Number Not appli- Designation Fulfilled...
  • Page 79 ALS 30x User Manual Number Not appli- Designation Fulfilled Remark Annex I cable 1.5.4. Errors of fitting 1.5.5. Extreme temperatures 1.5.6. Fire 1.5.7. Explosion 1.5.8. Noise 1.5.9. Vibrations 1.5.10. Radiation 1.5.11. External radiation 1.5.12. Laser radiation 1.5.13. Emissions of hazardous materials and substances 1.5.14.
  • Page 81 Novexx Solutions GmbH Ohmstraße 3 85386 Eching Germany  +49-8165-925-0 www.novexx.com...

This manual is also suitable for:

Als 30 seriesAls 309