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Summary of Contents for Avery Dennison ALS 309
- Page 1 ANUAL Label Dispenser Edition 7 (4/2010)
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Page 3: Table Of Contents
ONTENTS Please note Label sensor ......17 Power supply ......17 1.1 General notes Electronics . - Page 4 ONTENTS Before operation 4.2.2 Monitoring functions ....50 Material end / Roll diameter....50 3.1 Electrical connections Missing labels .
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Page 5: Please Note
Contents Copyright The present manual refers exclusively to the ALS 30x Avery Dennison holds all rights to this manual and its label dispensers. It is written for the purpose of appendices. Reproduction, reprinting or any other ensuring professional usage and calibration of the unit. -
Page 6: Illustrations And Descriptions
LEASE NOTE 1.1 G ENERAL NOTES Illustrations and descriptions 1.1.2 Signs and symbols Figures Various information types are indicated in different Texts are accompanied by figures where necessary. ways within the document in order to simplify Figures are indicated using figure numbers in [square readability and comprehension. -
Page 7: Safety Instructions
LEASE NOTE 1.2 S AFETY INSTRUCTIONS SAFETY INSTRUCTIONS Information and qualifications Ensure the required qualifications are met 1.2.1 Ensure that only trained and authorized personnel Follow the instructions operate, configure and service the unit. WARNING! Only allow qualified and well-trained expert personnel or service technicians to perform Safe and efficient operation of the label configurations. -
Page 8: Operational Safety Of The Unit
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Operational safety of the unit 1.2.2 Proper usage Only link the unit to devices that fulfil the SELV (safety extra-low voltage) circuit re- The label dispenser is a fully automatic unit for atta- quirements specified in EN 60950. ching self-adhesive labels to products or packaging. -
Page 9: Protection Against Injuries By Mechanical Action
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Protection against injuries by mechanical action WARNING! Risk of injury due to moving and rapidly rotating parts! – Long hair, loose jewellery, long sleeves, and so on are not permissible when using the unit. Sufficient protective clothing must be worn. -
Page 10: Before Beginning Production
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Before beginning production 1.2.3 Due diligence of the operating company Due diligence of the user and the service technician Check that the safety installations are working properly. Ensure that the following prerequisites are fulfilled in Inspect the machinery for any visible damage. -
Page 11: Safety Notes On The Unit
LEASE NOTE 1.2 S AFETY INSTRUCTIONS Safety notes on the unit 1.2.4 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. The ‘Pinch Point’ warning [1A] note warns you of the danger posed by the machine’s rotating parts;... -
Page 12: Product Description
RODUCT DESCRIPTION 2.1 O VERVIEW R O DU C T D E SC R IPT IO N OVERVIEW Components 2.1.1 [2] ALS 306 Label Dispenser (right-handed version). - Page 13 RODUCT DESCRIPTION 2.1 O VERVIEW A Dancer arm Dispensing edge – Keeps the label material stretched tight evenly. – Pictured: fixed L-shape dispensing edge. – Arrests the rotation of the material roll if tension – Optional available are: swivelling L-shape diminishes.
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Page 14: Control Panel
RODUCT DESCRIPTION 2.1 O VERVIEW Control panel 2.1.2 STATUS Operating LED Online Lights up green when the device is switched on. Labels – – Error LED Lights up red when an error occurs. LCD display – Displays functions, configured values, operating [3] The ALS 30x control panel (in dispensing mode) A Operating LED states and error messages. -
Page 15: Connection Arrangement
RODUCT DESCRIPTION 2.1 O VERVIEW Connection arrangement 2.1.3 Connections on the rear side of the device 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) -
Page 16: Mode Of Operation
RODUCT DESCRIPTION 2.1 O VERVIEW Mode of operation 2.1.4 In labelling mode, the label web is first pulled from the label roll around the dancer arm [5A], which consistent- ly 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 17: Technical Specifications
Technical specifications 2.1.5 Characteristics Label sensor Dispensing speed Distance to peel edge ALS 306 max. 60 m/min L-shape dispensing ALS 309 max. 45 m/min edge: 19 mm Labelling halt precision at Transmission sensor: Wenglor OPT242-P800 the peeling edge: optical, NPN Variable speed: <... -
Page 18: Interfaces
ALS 306 726 x 389 x 386 mm current: 1500 mA 726 x 802 x 386 mm ALS 309 726 x 389 x 470 mm Inputs: 3x PNP/NPN, 24 V 726 x 802 x 470 mm Data interfaces:... -
Page 19: Environmental Conditions
RODUCT DESCRIPTION 2.1 O VERVIEW Environmental conditions Certificates – CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA Operating temperature: 5 to 40°C – The regulation DIN EN 55022 demands for class A Humidity: 30 to 85%, (non-con- devices the following text to be printed in the densing) manual: Noise... -
Page 20: Design Models
RODUCT DESCRIPTION 2.1 O VERVIEW Design models 2.1.6 The ALS 30x can be adapted to client requirements un- der several aspects: Aspect Adaption Conveyor direction Right-handed (RH) / Left-handed (LH) machine Mounting position Horizontal / vertical of the machine Top / side labelling Mounting point at Top / bottom / right / left / rear the machine... -
Page 21: Options
RODUCT DESCRIPTION 2.2 O PTIONS OPTIONS External control panel – An external control panel can be connected in addition 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 22: Pneumatic Dispensing Edge
RODUCT DESCRIPTION 2.2 O PTIONS 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 between the products or on the product surface. [13] Pneumatic dispensing edge Euro dispensing edge holder Enables a vertical fine adjustment of the dispensing... -
Page 23: Splice Unit
RODUCT DESCRIPTION 2.2 O PTIONS Splice unit The splice unit is an accessory for ALS 30x labellers, which are operated with two lateral unwinders. The unit makes it easier to bond start and end of the two label webs. Thus, the label web doesn´t have to be newly fed [16] Splice unit (A) Dust/Splash guard Additional sealing of the electrical connections and of... -
Page 24: Cable Kit For Internal Outer Diameter Control
RODUCT DESCRIPTION 2.2 O PTIONS 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 25: Printer
RODUCT DESCRIPTION 2.2 O PTIONS Printer If necessary, you can mount a hot stamp printer (not available from Avery Dennison) onto the holder rods of the dispensing edge. Example of use: Printing consecutive numbers onto la- bels. Applicator If it is not possible to label directly from the dispensing edge, you can fit an applicator to the label dispenser. -
Page 26: Operating Modes
RODUCT DESCRIPTION 2.3 O PERATING MODES OPERATING MODES Dispensing mode 2.3.1 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 27: Online Settings
RODUCT DESCRIPTION 2.3 O PERATING MODES Online settings The machine is in dispensing mode. To switch to the online settings mode: STATUS Press the button. Speed Offset – The display shows the dispensing speed [23A] and 12.2 fix the start offset [23C]. –... -
Page 28: Configuration Mode
RODUCT DESCRIPTION 2.3 O PERATING MODES Configuration mode 2.3.2 The machine is in dispensing mode. Switching to configuration mode: STATUS Press the button twice. OFFLINE – Display: OFFLINE – – Press the button. – Display: LABEL SETUP LABEL SETUP – LABEL SETUP is the name of the first menu that is currently active. -
Page 29: Functions
RODUCT DESCRIPTION 2.3 O PERATING MODES Functions MACHINE SETUP Every submenu contains functions for setting the unit controls. Figure [25] shows the button functions for changing MACHINE SETUP > Language settings using the function as MACHINE SETUP an example. Store Prod.Prof. MACHINE SETUP Language Language... -
Page 30: Function Descriptions
RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS FUNCTION DESCRIPTIONS Overview of functions 2.4.1 (continued) (continued) LABEL SETUP MACHINE SETUP INTERFACE PARA > EASYPLUGINTERPR Load prod.profil Dispenser type Light sens. type Port address Gap detect mode Store prod.prof. Labelsen. InType Interface Ethernet speed Dispense speed Del. - Page 31 RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS (continued) (continued) SIGNAL INTERFACE SERVICE/DIAGNOS. SERVICE DATA > AI BOARD SIGNAL Interface mode Service > MODULE FW VERS. Manufacturer > PLC SIGNALS Applicator type Serv. data reset System version Work place End dispense mod Apply mode Sensor Test System revision...
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Page 32: Notes
– Setting range: ALS 306: [5.0…60.0] m/min; default: 10.0 Settings of functions that are not described in ALS 309: [5.0…45.0] m/min; default: 10.0 the following may only be changed by qualified – See chap. “Dispensing speed” on page 48. service technicians. These functions are described in the service manual. -
Page 33: Machine Setup Menu
RODUCT DESCRIPTION 2.4 F UNCTION DESCRIPTIONS MACHINE SETUP menu 2.4.4 Label 2 offset function: – Defines the distance of the 2nd label for the Store prod. prof. function: LABEL SETUP > Multi label mode function (see above). – Storing a product profile, see chap. “Storing a prod- The distance is measured from the front label edge uct profile”... -
Page 34: Before Operation
EFORE OPERATION 3.1 E LECTRICAL CONNECTIONS E FO R E O PE R AT IO N ELECTRICAL CONNECTIONS Power supply connection 3.1.1 WARNING! This machine operates using mains voltage! Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns. -
Page 35: Connecting Sensors
EFORE OPERATION 3.1 E LECTRICAL CONNECTIONS Connecting sensors 3.1.2 Check whether the required sensors are connected before turning on the unit [32]. The minimum required sensors: – Label sensor (installation location: dispensing edge) – Product sensor (installation location: conveyor belt) Additional optional sensors: –... -
Page 36: Inserting Label Material
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL INSERTING LABEL MATERIAL Prerequisites 3.2.1 – The label dispenser is turned off at the main switch [34A] (switch set to ‘O’). Check that the safety installations are working properly. Inspect the machinery for any visible damage. Report any defects immediately. -
Page 37: Inserting A Label Roll
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Inserting a label roll 3.2.2 WARNING! Risk of injury due to moving and rapidly rotating parts! Before inserting the label roll, ensure that the device is turned off at the main switch. Do not under any circumstances turn the device on before the label web is threaded in completely. -
Page 38: Threading Diagrams
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Threading diagrams 3.2.3 [37] Threading guide for ALS 30x (dotted line = roll with labels facing inwards). - Page 39 EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL [38] Threading guide for ALS 30x with a 45° rotated dispensing edge (dotted line = roll with labels facing inwards).
- Page 40 EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL [39] 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: –...
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Page 41: Threading The Label Web At The Dispensing Edge
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Threading the label web at the dispensing edge Fixed [40] 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 [40A] and through the slot in the sensor [40B]. -
Page 42: Threading The Label Web Onto The Drive Roller
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Threading the label web onto the drive roller Open the pressure roller. To do so, rotate the lever [43A] in a clockwise direction. Feed the backing paper around the deflection rollers [43B] and the drive roller [43C]. Close the pressure roller. -
Page 43: Splice Unit Application
EFORE OPERATION 3.2 I NSERTING LABEL MATERIAL Splice unit application 3.2.4 The splice unit is an accessory for ALS 30x labellers, which are operated with two lateral unwinders. The unit makes it easier to bond start and end of the two label webs. -
Page 44: Mechanical Settings
EFORE OPERATION 3.3 M ECHANICAL SETTINGS MECHANICAL SETTINGS Adjusting the unwinder’s core 3.3.1 diameter Tool: – 3 mm hexagon (Allen) screwdriver The unwinder can be adjusted with core adapters [50A] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter: –... -
Page 45: Positioning The Label Sensor
EFORE OPERATION 3.3 M ECHANICAL SETTINGS Positioning the label sensor 3.3.3 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 LED [53A] lights up when the sensor is positioned over a label. -
Page 46: Operation
PERATION 4.1 S TART UP AND SHUTDOWN P E RA TIO N START-UP AND SHUTDOWN Turning on the unit Dispensing without a product sensor 4.1.1 It is also possible to trigger the dispensing process without a product sensor: – The machine is in dispensing mode: Press the button. -
Page 47: Configuration And Monitoring
PERATION 4.2 C ONFIGURATION AND MONITORING CONFIGURATION AND MONITORING Function menu settings 4.2.1 Label pitch Switch to configuration mode Calibrating the label pitch automatically: Hold down the button for a while (longer than two seconds). Or: Enter the label pitch manually: Measure the label pitch [57C]. -
Page 48: Dispensing Speed
PERATION 4.2 C ONFIGURATION AND MONITORING Dispensing speed You can set the dispensing speed to a fixed value or you can configure it to automatically adjust to the speed of the conveyor belt (speed adaption). The second option requires you to connect a rotary encoder that measures and relays the conveyor speed to the dispenser. -
Page 49: Label Position On The Product
PERATION 4.2 C ONFIGURATION AND MONITORING Label position on the product Prerequisites: – The label length must be specified. – The label stop position must be set. Configuration in dispensing mode: Use the two right buttons to set the start offset (see “Online settings”... -
Page 50: Monitoring Functions
PERATION 4.2 C ONFIGURATION AND MONITORING Monitoring functions 4.2.2 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 of the material roll is reached. -
Page 51: Missing Labels
PERATION 4.2 C ONFIGURATION AND MONITORING If an error message occurs: – The machine stops. Press the button to delete the message. Remove the rewound backing paper. Insert a new material roll (see “Inserting a label roll” on page 37). Missing labels A label missing from the label roll does not normally affect the dispensing operation, because the label feed... -
Page 52: Using Product Profiles
PERATION 4.3 U SING PRODUCT PROFILES USING PRODUCT PROFILES What are product profiles? Storing a product profile 4.3.1 4.3.3 Product profiles are memory locations that can store all Selecting the memory location the settings for the machine controls. For recurring MACHINE SETUP >... -
Page 53: Deleting A Product Profile
PERATION 4.3 U SING PRODUCT PROFILES – The profile is saved. – Display: Store prod.prof. Storing… – The product profile has now been saved. Deleting a product profile 4.3.4 MACHINE SETUP > Del. prod.profil Call the function. – The memory location that was active last is displayed. -
Page 54: After Operation
FTER OPERATION 5.1 M AINTENANCE AND CLEANING FT ER O P ER A TIO N MAINTENANCE AND CLEANING Cleaning agents 5.1.1 Cleaning agents for rubber rollers: – Roller cleaner, order number 98925. If other cleaning agents are used, there is a chance the rubber may corrode. -
Page 55: Regular Maintenance
FTER OPERATION 5.1 M AINTENANCE AND CLEANING Regular maintenance 5.1.2 The label dispenser 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: Wipe the paper residue from the rollers and edges. -
Page 56: Operational Failures
PERATIONAL FAILURES 6.1 S TATUS MESSAGES PE R AT IO N AL FA IL UR E S STATUS MESSAGES Types of status messages List of warnings 6.1.1 6.1.2 Error messages Displayed text Meaning When an error occurs, the machine stops immediately Produktstartwarn New start signal during the and displays an error message on the control panel. -
Page 57: List Of Error Messages
PERATIONAL FAILURES 6.1 S TATUS MESSAGES List of error messages 6.1.3 Status Status text Cause Action to take 5000 Bus device – Device at I C Bus cannot be Delete the message by pressing the contacted. -key. – In most cases, this message appears Switch the machine off, wait 30 as the first in a series of two or three seconds and switch it back on. - Page 58 PERATIONAL FAILURES 6.1 S TATUS MESSAGES Status Status text Cause Action to take 5140 Rewinder control Rewinder control Press the key. – This reinitialises the dancer arm During problem-free operation, control; the dancer arm moves back the rewind unit dancer arm only into the control position.
- Page 59 PERATIONAL FAILURES 6.1 S TATUS MESSAGES Status Status text Cause Action to take 5147 Tandemsynch. Init This message can only appear Check, if the slave machine had during tandem operation. been switched on before the master machine - if not, repeat the switching on in the correct order (first slave, –...
- Page 60 PERATIONAL FAILURES 6.1 S TATUS MESSAGES Status Status text Cause Action to take 9022 No network link This status message can only appear Check whether the network when Ethernet address assignment is connector is plugged in correctly, (INTERFACE PARA > set to DHCP correct if necessary.
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Page 61: Appendix
EU directives. Name of the devices: ALS 306, ALS 309 Device type: Label dispenser... - Page 63 Avery Dennison Deutschland GmbH Ohmstraße 3 85386 Eching Germany Telephone: +49-8165-925-0 http://www.machines.averydennison.com...
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