Printed in Germany For technical questions which are not addressed in this operating manual: ➔ Refer to the Service Guide for the ALS 380 Labeller Manufacturer Avery Dennison Deutschland GmbH ➔ consult the servicing technician of our sales partner.
LEASE OBSERVE THE FOLLOWING 1.1 G ENERAL INFORMATION Conventions and information 1.1.2 Explanation of symbols Illustrations In order to facilitate legibility and an overview, the vari- When required, text passages are accompanied by il- ous types of information used herein are categorised lustrations.
LEASE OBSERVE THE FOLLOWING 1.1 G ENERAL INFORMATION Directional information Unless otherwise indicated, the directional information mentioned in the text refers to the construction of the right-hand version of Top Labeller. See Figure [1] for the explanation of directional information. [1] Definition of directional information A Front B Rear...
LEASE OBSERVE THE FOLLOWING 1.2 S AFETY INSTRUCTIONS SAFETY INSTRUCTIONS Information and qualifications 1.2.1 Pay attention to the information Ensure necessary qualifications ➔ WARNING! Only allow the machine to be operated, adjusted and serviced by instructed and authorised person- Reliable and safe operation of the labeller is nel.
1.2.2 Appropriate use Protect against injuries that can result The ALS 380 labeller is a fully automatic machine for from mechanical actions the application of self-adhesive labels to products or packages. The machine is to be equipped by the oper-...
LEASE OBSERVE THE FOLLOWING 1.2 S AFETY INSTRUCTIONS Before every production start 1.2.3 Operator's obligation and service personal Operating personnels' obligation to exer- to exercise care cise care ➔ ➔ Ensure the following prerequisites correspond to the Verify flawless functioning of the safety equipment. information of the operating manual: ➔...
QUIPMENT DESCRIPTION 2.1 O VERVIEW Principle of operation A Unwind unit 2.1.2 – The unwinding spindle holds the label roll. – The spreader mechanism (chucking wedge) se- In labelling mode, the unwind unit [2A] and the drive cures the label roll. roller unit move the [2D] label ribbon.
Dispensing speed Dimensions 0.5 m/min to 80 m/min Width: 735 mm ALS 380: 0.5 m/min to 100 m/min Height: 795 mm ALS 380 HS: Depth: 400 mm Stop accuracy (at the Weight dispensing edge): ± 0.5 mm 50 kg ALS 380:...
QUIPMENT DESCRIPTION 2.1 O VERVIEW Design versions 2.1.4 The ALS 380 labeller is available in 4 different versions, depending on the taskat hand: Top-labeller right-hand version – Labelling from above onto the upper side of the product [3]. – The products are conveyed from left to right.
QUIPMENT DESCRIPTION 2.1 O VERVIEW Top-labeller left-hand version – Labelling from above onto the upper side of the product [5]. – The products are conveyed from right to left. – The dispensing edge is located on the left side. Side-labeller left-hand version –...
2.1 O VERVIEW Options 2.1.5 High-speed processing version Printer ALS 380 HS – Inkjet or heat transfer printer at the dispenser head. – Allows dispensing speeds up to 100 m/min – Available in all of the above-mentioned design ver- Applicator sions.
Keys FEED – When this key is pressed, the machine dispenses a label. [7] Operator panel for the ALS 380 PRIOR (previous function) A LED indicator B FEED key – Paging through the functions in the menu: to see the C PRIOR key previous function, page upward.
QUIPMENT DESCRIPTION 2.2 O PERATOR CONTROLS Main switch 2.2.2 – The main switch [8] is located to the left on the housing. – The main switch is used to switch the machine on and off. WARNING! Contact with energised components can re- sult in life-endangering currents through the body as well as burns.
QUIPMENT DESCRIPTION 2.3 C ONTROL SYSTEM CONTROL SYSTEM Brief description 2.3.1 All of the machine’s functions are electronically It is also possible to modify the basic machine settings. controlled. Using the operator panel, the operators, cal- These are settings such as the motor’s direction of ro- ibration technicians, or service personnel have several tation.
QUIPMENT DESCRIPTION 2.3 C ONTROL SYSTEM Menus for operators and calibration technicians 2.3.2 Menu Standard menu Extended menu Product databanks Functions INIT INIT PD01 VELO VELO PD02 STOD STOD PD03 PD04 POS 2 PD05 POS 3 PD06 VERT PD07 CONT PD08 E–SS PD09...
QUIPMENT DESCRIPTION 2.3 C ONTROL SYSTEM Monitoring functions 2.3.3 During labelling operation, the electronic control sys- tem and the sensors monitor the following functions. Dispensing a label to each product – A photoelectric sensor (product sensor) sends a sig- nal when a product reaches the dispensing edge [9B].
RIOR TO OPERATING 3.1 I NSERT THE LABELLING MATERIAL RI O R TO O P ER A TIN G INSERT THE LABELLING MATERIAL Prerequisites 3.1.1 – The label dispenser is switched off at the main [11A] switch. ➔ Verify flawless functioning of the safety equipment. ➔...
RIOR TO OPERATING 3.1 I NSERT THE LABELLING MATERIAL Insert new label roll Only top-labeller: ➔ Loosen the set-screw at the guiding rod [13C] and swing the guiding rod to the side. All design versions: ➔ Rotate the knurled knob [13B] clockwise, to retract the chucking wedge [13A] in the unwinding spindle.
RIOR TO OPERATING 3.1 I NSERT THE LABELLING MATERIAL Threading the label ribbon 3.1.3 Overview of the threading path diagram [14] Threading path diagram for label ribbon with the labels on the outside A Right-hand version B Left-hand version [15] Threading path diagram for label ribbon with the labels on the inside A Right-hand version B Left-hand version...
RIOR TO OPERATING 3.1 I NSERT THE LABELLING MATERIAL Thread the label ribbon at the unwind unit. ➔ Swing up the pressure roller [16B] and the braking brush [16C]. ➔ Thread the label ribbon around the deflection roller [16E], dancer armroller [16A] and drive roller unit [16D].
RIOR TO OPERATING 3.1 I NSERT THE LABELLING MATERIAL Thread in the label ribbon at the dispens- ing edge. ➔ Swing up the pressure roller [17D] behind the dis- pensing edge. ➔ Unthread approximately 2 m of label ribbon from the label roll.
RIOR TO OPERATING 3.1 I NSERT THE LABELLING MATERIAL Thread the label ribbon at the rewind unit. ➔ Thread the label ribbon around the deflection rollers and the dancer armrollers as shown in figure [18]. ➔ Open the spreader mechanism of the rewinding roll- er using the lever [18C].
RIOR TO OPERATING 3.2 M ECHANICAL SETTINGS MECHANICAL SETTINGS WARNING! Risk of injury due to moving or rapidly rotat- ing parts! ➔ Before carrying out the mechanical set- tings, ensure that the machine is switched off at the main switch. Setting the ribbon guides 3.2.1 Operator panel support...
RIOR TO OPERATING 3.2 M ECHANICAL SETTINGS Adjusting the braking brushes 3.2.2 Mounting locations of the braking brushes: – In front of the operator panel support [20A] – On the vertical guide for the dispensing edge [20B] ➔ Loosen the stud bolt [20C]. ➔...
RIOR TO OPERATING 3.2 M ECHANICAL SETTINGS Adjusting the pressure rollers 3.2.3 Mounting locations of the pressure rollers: – On the drive roller unit of the unwind unit – On the drive roller unit of the label feed ➔ Loosen the knurled thumb screws on the setting rings [21A].
RIOR TO OPERATING 3.2 M ECHANICAL SETTINGS Adjust the pressure roller unit 3.2.4 (optional) at the dispensing edge. Depending on the area of application, the labeller can be equipped with an additional pressure roller unit [22A] at the dispensing edge. The most favourable positioning of the pressure roller unit differs depending on the application.
RIOR TO OPERATING 3.2 M ECHANICAL SETTINGS Adjust (optional) the position 3.2.5 of the dispensing edge. Adjusting vertically Coarse adjustment: ➔ Open the central lock [23B]. ➔ Hold the dispenser head firmly and open the lower lock [23C]. ➔ Slide the dispenser head to the desired height and tighten the lock [23C].
PERATION 4.1 A CTIVATION AND SHUT DOWN P E RA TI ON ACTIVATION AND SHUT-DOWN Starting the machine 4.1.1 Before each use, the control system must be adapted to the inserted label material. During this, the label dis- tance is detected and the photoelectric sensor at the dispenser head is adapted to the transparency of the labels and of the backing material.
PERATION 4.1 A CTIVATION AND SHUT DOWN The machine can also be automatically initial- ised after switch-on by using the INIT function: ➔ In the standard menu, press the NEXT or PRIOR key until INIT [26] is displayed on the operator pan- ➔...
PERATION 4.1 A CTIVATION AND SHUT DOWN Labelling 4.1.2 Prerequisites – Label material is inserted. – Machine is switched on. – Material is initialised. If "OFF" appears on the operator panel: ➔ Press the ENTER [28] key until ON [29A] is shown. [28] ENTER key If "ON"...
PERATION 4.1 A CTIVATION AND SHUT DOWN Start dispensing labels – The conveyor belt starts up. The first product reach- es the product sensor (photoelectric sensor) [30]. – The product sensor sends a start signal. – The start signal from the product sensor triggers the dispensing of a label (label feed) using the set val- ues for dispensing speed, label distance, etc.
[31B]. – If necessary, the control system automatically slows the rewinding speed. The dispensing speed is not [31] ALS 380 in labelling mode affected by this. Stop/end the label dispensing 4.1.3 ➔...
PERATION 4.1 A CTIVATION AND SHUT DOWN Tandem operation 4.1.4 [33] Two labellers in tandem arrangement A The active labeller, label roll comes to its end B Labeller in standby with full label roll, “LOCK” appears on the operator panel Principle of operation In tandem operation, two labellers are arranged one During automatic switch-over from one machine to the...
Press the ENTER key. – The operator panel of this machine indicates LOCK. Start dispensing labels [34] Operator panel for the ALS 380 – The conveyor belt starts up. The first product reach- A “ON" LED indicator B ENTER key es the product sensor [35A] of the activated ma- chine.
PERATION 4.1 A CTIVATION AND SHUT DOWN Reloading label material WARNING! Risk of injury from the running conveyor line at the workplace! Risk of pinching at the dis- pensing edge! ➔ Before reloading label material, ensure that the machine in question does not start up unintentionally.
PERATION 4.1 A CTIVATION AND SHUT DOWN Switching off Switch over the active machine On the operator panel of the active machine: ➔ Press the FEED [37] key. – The indication on the operator panel changes from ON to BUSY, until the machine stops. –...
PERATION 4.2 S ETTING AND MONITORING SETTING AND MONITORING Settings in the standard menu 4.2.1 Overview Function/ Brief description Display Activate labelling mode End labelling mode INIT Automatic material initialisation VELO Dispensing speed STOD Distance between dispensing edge and leading edge of the label Distance between leading edge of product and label [38] Functions in the standard menu Calling up menu...
PERATION 4.2 S ETTING AND MONITORING Label stop position 4.2.2 (STOD) After the label is output, the feed continues to operate, until the next label is present at the dispensing edge. To ensure that the labels separate completely from the dis- pensing edge, it is advisable to allow the feed to run un- til the next label projects slightly over the dispensing edge.
OR key. – Settings are permitted in steps of 0.1 m/min: Minimum: 0.5 m/min Maximum: 80 m/min (ALS 380 HS: to 100 m/min) – Confirm the setting using the ENTER key and exit the VELO function. [44] VELO display on the operator panel Test the setting: ➔...
PERATION 4.2 S ETTING AND MONITORING Label position on the product 4.2.4 (POS) – Distance between leading edge of the product and leading edge of the label [45A] Prerequisites: – The label stop position (STOD) is correctly set. – The dispensing speed (VELO) is correctly set. ➔...
PERATION 4.2 S ETTING AND MONITORING Automatic material 4.2.5 initialisation (INIT) Also refer to chapter Activation and shut-down. ➔ In the standard menu, press the NEXT or PRIOR key until INIT [48] is displayed on the operator pan- ➔ Call the INIT function by pressing the ENTER key. ➔...
PERATION 4.2 S ETTING AND MONITORING If errors occur 4.2.6 Warning messages If the machine control system detects a malfunction, but the labelling operation does not have to be inter- rupted: – A warning message appears on the LED-indicator of the operator panel. –...
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PERATION 4.2 S ETTING AND MONITORING Error messages If the machine control system detects a serious mal- function: – The labelling operation is automatically halted. – An error message appears on the LED-indicator of the operator panel. – A warning message is displayed in the format E_nn: E stands for error, nn is a two-digit numerical code.
PERATION 4.3 P RODUCT DATABANKS PRODUCT DATABANKS Functions Loading product data banks 4.3.1 4.3.2 Please observe: Task-specific settings that do not need to be modified for daily operation: CAUTION! Erroneous settings can lead to production – POS – MLAB setbacks, damage to the machine and sys- –...
PERATION 4.3 P RODUCT DATABANKS Activating product databanks at switch-on – The menu Product databanks is only available if at least one product databank is created. ➔ While switching on the machine, press and hold the PRIOR key. – The product databank menu is activated. –...
PERATION 4.3 P RODUCT DATABANKS Create/save product databank 4.3.3 Prerequisites Saving the product databank CAUTION! In the extended menu: ➔ Call up the SAVE function. Erroneous settings can lead to production ➔ Select the desired product databank using the setbacks, damage to the machine and sys- NEXT or PRIOR key.
PERATION 4.3 P RODUCT DATABANKS Deleting a product databank 4.3.4 In the extended menu: ➔ Call up the DEL function. ➔ Select the desired product databank using the NEXT or PRIOR key. – Only product databanks that contain data are shown.
(not with ALS 380 HS, see Service Guide) TMOD Activate and deactivate tandem operation LOAD Loading product data banks SAVE Create and save a product data bank Deleting a product databank QUIT Exit the extended menu [54] Functions in the extended menu of the ALS 380...
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PERATION 4.4 S ETTINGS IN THE EXTENDED MENU In addition, when using a printer (optional): Print delay PDWT Printer dwell time [55] Additional functions for printers Additional functions when using an Applicator (optional): APPL Set the applicator type used APT1 Set the dwell time for the EP cylinder APT2 Dwell time for blowing the label on the product...
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Activating an extended menu 4.4.2 Please observe: CAUTION! Erroneous settings can lead to production setbacks, damage to the machine and sys- tem, and can even cause work-related acci- dents! – Only specially trained and instructed per- sonnel may alter the settings in the ex- tended menu.
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Position of second label 4.4.3 (POS2) If the products are to be given two labels: – Distance between the leading edges of the first and second label [58A]. In the extended menu: ➔...
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Speed ratio (VERT) 4.4.5 – Relationship between the dispensing speed and the conveyor belt speed Example [60]: Circumferential labelling of a round prod- uct. The product simultaneously makes a linear move- ment and a rotational movement. In the extended menu: ➔...
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Adjust the label stop sensor (CONT) 4.4.6 Technology Automatically adjusting the photoelectric sensor Automatic and manual adjustment ➔ Press and hold the FEED key and switch on the ma- The sensitivity of the label stop sensor must be adjust- chine at the main switch.
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Manually adjusting the sensor. In the extended menu: ➔ Call up the CONT function. ➔ Insert the backing material without a label under the photoelectric sensor. ➔ Press the PRIOR key until the yellow LED on the photoelectric sensor [61A] illuminates.
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Label distance (LPIT) 4.4.7 The label distance is defined as [62]: Label distance = label length + gap The shape of the labels or reflective surfaces can cause a false signal to be sent from the label stop sen- sor.
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Distance from the label stop 4.4.8 sensor to the dispensing edge (E–SS) – Correct specification of the distance between the la- bel stop sensor and the dispensing edge is a prereq- uisite for setting the label stop position (STOD). Set distance ➔...
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Check setting ➔ Call up the STOD function. ➔ Set the value for STOD to "0". ➔ Confirm the value using the ENTER key and exit the function. ➔ Press the FEED key. –...
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Product length (PRDL) 4.4.9 A start signal can be prematurely triggered by the shape of the product or reflective surfaces. In such a case, the product length must be manually set. Example [67]: If the product [D] reaches the product sensor [C], a start signal is sent and the machine dispenses a label.
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Polarity of the product sensor 4.4.10 (P_S_) The product sensor can optionally send the start signal, – the leading edge of the product passes the sensor [68A]. – the trailing edge of the product passes the sensor [68B].
4.4.13 of the RPM transmitter (EGRA) – Compensation factor for RPM transmitter when op- erating with automatic dispensing speed adjustment – Refer to chapter Automatic dispensing speed (APSF), page 67. – For ALS 380 HS, refer to the Service Guide...
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Advance print start (PDT) 4.4.14 When using a printer (optional): The printing process can be started even in the final phase of the label feed. In so doing, the printer stamp is already moving toward the label ribbon, even before the label has come to a standstill - this shortens the printing process.
PERATION 4.4 S ETTINGS IN THE EXTENDED MENU Tandem operation (TMOD) Delete a product data bank 4.4.16 4.4.22 load (LOAD) Activate and deactivate tandem operation – Refer to chapter Tandem operation in the service Selecting and loading a product data bank. guide.
ALS 380. The control system the dispensing speed and the conveyor belt speed calculates the permanent position and speed of the must be finely adjusted (the EGRA function).
4.5.1 of the RPM transmitter (EGRA) – Required compensation factor for the RPM trans- mitter – For ALS 380 HS, refer to the Service Guide Setting the compensation factor ➔ Calculate the setting value for EGRA: A= resolution of the RPM transmitter used in mm/pulse –...
PERATION 4.6 A PPLICATOR OPTIONAL APPLICATOR (OPTIONAL) Principle of operation 4.6.1 If direct labelling from the dispensing edge is not possi- ble, the labeller can be equipped with an applicator. In applicator mode, the applicator takes the label from the dispensing edge and carries it to the product.
PERATION 4.6 A PPLICATOR OPTIONAL Functions in the extended menu 4.6.2 Please observe the following CAUTION! Erroneous settings can lead to production setbacks, damage to the machine and sys- tem, and can even cause work-related acci- dents! – Only specially trained and instructed per- sonnel may alter the settings in the ex- tended menu.
PERATION 4.6 A PPLICATOR OPTIONAL EP cylinder dwell time (APT1) – Dwell time for the EP cylinder In the extended menu: ➔ Call up the APT1 function. ➔ Set the desired value. – Settings are possible in 1 ms steps: 1 ...
PERATION 4.6 A PPLICATOR OPTIONAL Fine tuning of the dwell time (APT4) When using an applicator in combination with the auto- matic speed adjustment (APSF): – Optimise the accuracy of the label position on the product by fine tuning the dwell time for the applica- tor.
FTER OPERATION 5.1 C ARE AND CLEANING FT ER O P ER A TIO N CARE AND CLEANING Cleaning agents Regular maintenance 5.1.1 5.1.2 Cleaning agents for rubber rollers: The ALS380 labeller is designed to be mainte- – Roller cleaner, ordering code 98925 nance-free.
FTER OPERATION 5.1 C ARE AND CLEANING Remove paper waste ➔ Wipe off all paper waste (dust) from all rollers and edges. ➔ Clean the optics of the photoelectric sensors with a soft brush or a soft tissue. Braking brushes ➔...
FTER OPERATION 5.1 C ARE AND CLEANING Capacitive sensor at the dispenser head Only if the labeller is equipped with a capacitive sensor [76A] instead of the proper photoelectric sen- sor: ➔ Remove the knurled thumb screw [76B]. ➔ Remove 2 screws on the underside [77A]. ➔...
PERATIONAL MALFUNCTIONS 6.1 W ARNING MESSAGES P E RA TI ON A L M AL FU NC TI ON S WARNING MESSAGES Please observe: If a problem occurs 6.1.1 6.1.2 CAUTION! The control system detects a problematic or unaccept- able situation: Improper handling of the machine, especial- –...
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PERATIONAL MALFUNCTIONS 6.1 W ARNING MESSAGES Message Description Possible causes and remedies W__2 Memory errors CPU battery is discharged after a long shut-down period of Factory settings are activated, see the machine: ➔ appendix. Leave the machine switched on for some time to re- charge the battery If the accumulatorerror occurs frequently: ➔...
PERATIONAL MALFUNCTIONS 6.2 E RROR MESSAGES ERROR MESSAGES If a malfunction occurs 6.2.1 If the control system detects a serious error: If the cause of the error has been eliminated: ➔ – The labelling operation is stopped. Acknowledge the error message by pressing the –...
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PERATIONAL MALFUNCTIONS 6.2 E RROR MESSAGES Message Description Possible causes and remedies E__2 Label stop sensor does not detect Ribbon of labels does not run through the slot in the photoe- the labels. lectric sensor: ➔ Check the ribbon guide at the label stop sensor. Label roll empty or more than 3 labels missing: ➔...
A serious memory error has occurred: Factory settings are activated, see – The control system needs to be reconfigured by a appendix. servicing technician or Avery Dennison’s custom- er service; refer to the Service Guide. ➔ E_13 Label roll is completely consumed.
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PERATIONAL MALFUNCTIONS 6.2 E RROR MESSAGES Message Description Possible causes and remedies E_15 Short circuit A check of the connections and output signals by servicing technicians is required; refer to the Service Overload of outputs from CN10 Guide. ER-U Software error ➔...
PPENDIX 7.1 F ACTORY SETTINGS P PE ND IX FACTORY SETTINGS In the case of a memory error: – The message W__2 or E_12 appears on the operator panel. – All databanks are deleted. – The settings of the machine are reset to fac- tory settings [79].
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PPENDIX 7.1 F ACTORY SETTINGS Function Value Explanation APPL Applicator mode off APT1 0001 EP applicator dwell time 1 ms APT2 0001 EP applicator blow time 1 ms APT3 0000 EP applicator: Delay of the signal air blow: 0 ms APT4 0001 Applicator operation with APSF –...
PPENDIX 7.2 P RODUCT DATA BANKS PRODUCT DATA BANKS Client/Order PD01 PD02 PD03 PD04 PD05 PD06 Function Data bank POS2 POS3 VELO STOD CONT E–SS LPIT PRDL P_S_ S_S_ MLAB PDWT EGRA VERT APPL APT1 APT2 APT3 APT4 Date: Signature:...
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PPENDIX 7.2 P RODUCT DATA BANKS Client/Order PD07 PD08 PD09 PD10 PD11 Function Data bank POS2 POS3 VELO STOD CONT E–SS LPIT PRDL P_S_ S_S_ MLAB PDWT EGRA VERT APPL APT1 APT2 APT3 APT4 Date: Signature:...
ECLARATION OF ONFORMITY EC DECLARATION OF CONFORMITY We, the: Avery Dennison Deutschland GmbH Ohmstraße 3 D–85386 Eching declare that we have designed and constructed the following designated machine in such a way that it complies with the basic safety and health requirements of the EC Directive.
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