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Avery Dennison ALS 230 User Manual

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Release 12/07
Artikelnummer: 0089999-02

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Summary of Contents for Avery Dennison ALS 230

  • Page 1 Release 12/07 Artikelnummer: 0089999-02...

  • Page 3: Table Of Contents

    Operators Manual ALS 230 Contents 1. Important Notes......................4 1.1 Overview............................4 1.1.1 Manufacturer........................4 1.1.2 Copyright..........................4 1.2 Safety............................5 1.2.1 General Safety Notes ......................5 1.2.2 Warning Notes in the Text ....................5 1.2.3 Operator’s duty of care ...................... 6 1.2.4 Concrete security regulations and symbols used ..............
  • Page 4 Operators Manual ALS 230 4.4 Control of dispense unit ......................25 4.4.1 Dispenser Menu selection....................25 4.4.2 Missing label function and web breaks ................26 4.4.3 Display and data input......................27 1.3 Maintenance ..........................30 5. Menu structure ....................... 31 5.1 Standard menu ...........................33 5.2 Extended standard menu......................35 5.3 Product menu..........................41...
  • Page 5 Operators Manual ALS 230 10.3 APSF- Sensor Specification (Optional function) ................ 78 10.4 Performance ..........................79 10.4.1 Labels per minute in relation to different label pitches ............ 79 10.4.2 Dispensing speed reached while dispensing certain label length ........80 11. Adjustment ......................83 12.

  • Page 6: Important Notes

    1. Important Notes 1.1 Overview The AVERY ALS 230 is a fully automatic labeller. Handling is very easy and can be learned with a minimum of training. For operation, only a few adjustments are necessary. The machine is controlled by a microprocessor and because of its programmable functions, it can be used in many applications.

  • Page 7: Safety

    Operators Manual ALS 230 1.2 Safety 1.2.1 General Safety Notes In order to avoid any risk of injury due to squeezing between the fixed dispensing edge and the passing product, it may be necessary to add a protection cover in front of the dispensing edge.

  • Page 8: Operator's Duty Of Care

    Operators Manual ALS 230 1.2.3 Operator’s duty of care The machine was designed and constructed taking into account a hazard analysis and after careful selection of the harmonised standards to be observed, as well as other technical specifications. Thus, it corresponds to the state of the art and allows the highest possible degree of safety during operation.

  • Page 9: Concrete Security Regulations And Symbols Used

    Operators Manual ALS 230 1.2.4 Concrete security regulations and symbols used In the following operating instructions, concrete security regulations are indicated in order to point out the remaining risks which cannot be avoided when operating the machine. These remaining risks include danger to •...

  • Page 10: Security Measures During Normal Operation

    Operators Manual ALS 230 1.2.5 Security measures during normal operation The machine may only be operated by trained and authorised persons who are familiar with the operating instructions and are able to work in accordance with it! • Before starting the machine, check and make sure that •...

  • Page 11: Work On The Electrical Equipment

    Operators Manual ALS 230 1.2.7 Work on the electrical equipment Repair work on the electrical equipment of the machine may only be performed by a trained electrician! Electrical equipment must be checked on a regular basis! Loose connections must be fixed again!

  • Page 13: Description

    Operators Manual ALS 230 2. Description CAUTION! - The machine is connected to mains. Only authorised personnel may open the cover. Operation without this cover is not allowed. This chapter explains the structure and the function of the labeller. The expressions used are explained here.
  • Page 14 Operators Manual ALS 230 Figure 1 Dispensing mechanics At the dispensing edge (010) the label is separated from the backing paper. By means of a soft (005) roller the label is applied on to the product. Roller (012) makes sure that the material is always guided properly around the dispensing edge.

  • Page 15: Operator Panel

    Operators Manual ALS 230 Dispensing is only possible when the handle (015) is in the closed position. Via the deviator roller (016) the backing paper is guided to the rewind mandrel (017). The cone between the 4 pins can be pulled out to allow the reward backing paper to be removed.
  • Page 16 Operators Manual ALS 230 PRIOR: This key moves up the menu (prior function) or increases the value of a parameter. If the up arrow key is pressed and held as the machine is turned on the product menu is selected.

  • Page 17: Plug Board

    Operators Manual ALS 230 2.3 Plug board The plug board is shown in Figure 3. Beside the mains switch and the mains cable socket there are some more holes for optional functions. Standard execution in this machine is one I/O plug prepared for the product sensor.
  • Page 18 Operators Manual ALS 230 Release 12/07 Page 16 Description...

  • Page 19: Preparing The Machine

    Operators Manual ALS 230 3. Preparing the machine In this chapter you will learn how to install and adjust the labeller. After this step has been completed you will be ready to learn how the labeller's parameters can be adjusted to suit your particular production requirements.

  • Page 20: Define Label Data

    Operators Manual ALS 230 1.2.2 Define label data For correct dispenser operation, you have to tell the machine the length of the label and adjust the label sensor. Normally this is done automatically. For this follow the instructions in chapter Operation / Initialise material.
  • Page 21 Operators Manual ALS 230 Setting LPIT manually To initialise labels with cut outs such as the one shown below - the "LPIT" parameter should be used to enter the label pitch of the label web. Label sensor LPIT real leading...

  • Page 22: Capacitive Label Sensor

    Operators Manual ALS 230 Capacitive label sensor For transparent labels the standard photo label sensor doesn’t work. In this case, use a mechanic or a capacitive label sensor. Note: For correct automatic initialisation, the CONT parameter has to be set to a manual value, if you using not the standard photo sensor.

  • Page 23: Label Guide

    Operators Manual ALS 230 3.1 Label guide On some of the axles, they’re guiding clamps. Adjust the clamps near the machine so all have the same distance to the front plate (31.5mm). The outer clamps should be mounted that the guide but not bend the label material.

  • Page 24: Fixed Dispensing Speed

    Operators Manual ALS 230 3.2.1 Fixed dispensing speed The second step is to adjust the dispense speed. If an APSF sensor is used see 3.2.2. If an applicator is used, then the dispense speed has no influence to the dispense process.

  • Page 25: Operation

    Operators Manual ALS 230 4. Operation This chapter describes the operation of the machine. 4.1 Safety recommendation CAUTION! Before connections to the mains check the correct voltage selection. Use only original spare parts for service. Open of the cover is only allowed authorised personal.

  • Page 26: Initializing New Label Material

    Operators Manual ALS 230 left hand version right hand version Figure 7 Threading diagram Hang document material in reel holder in a way to ensure unwinding that label in the printer section is on the top. Put outer guide disk onto mandrel. The two guide plates keep the label roll reliably in position on the unwind mandrel.

  • Page 27: Control Of Dispense Unit

    Operators Manual ALS 230 executed by pressing the <FEED key> whenever the message "INIT" is displayed by the machine. The message "INIT" is displayed in the following cases: a) if the <FEED> key is pressed and held during power up b) on return to the standard menu after the "CONT"...

  • Page 28: Missing Label Function And Web Breaks

    Operators Manual ALS 230 If you do not press a panel key while turning on the machine the same menu is active that has been used before the machine was switched off. 4.4.2 Missing label function and web breaks The missing label function stops the label web in the correct position even when a label is missing from the label web.

  • Page 29: Display And Data Input

    Operators Manual ALS 230 4.4.3 Display and data input The operator panel controls the operation of the machine. Data can be displayed and changed. The displays have different meanings: Parameter selection: In the display a parameter is shown, e.g. POS, STAD, or PD02 (product menu no. 02). By pressing the keys FUNCTION another parameter can be selected.
  • Page 30 Operators Manual ALS 230 Dispenser stopped ________________________________________________ OFF The dispenser function is stopped. Single labels could be dispensed with the FEED key. Material initialisation _______________________________________________ INIT A new initialisation of material is necessary. Pressing the FEED key will start the initialisation.
  • Page 31 Operators Manual ALS 230 Stop position ___________________________________________________ STOD The stopping position (STOD) defines the position where the label stops after it has passed the label sensor. The value represents 1/10 mm. In the example 0160 has to be adjusted by pressing the FUNCTION keys.

  • Page 32: Maintenance

    Operators Manual ALS 230 Blow on time ___________________________________________________ BLOW The labelling time BLOW indicates, for how long the applicator should apply the label onto the product. This time is displayed in ms also. BLOW is equivalent to APT2, which is found in the extended menu.

  • Page 33: Menu Structure

    Operators Manual ALS 230 5. Menu structure The touch panel keys or the optional interface can change labeller parameters. The last entered parameters are the actual ones the machine works with. Programming via the interface is described in chapter Serial interface.
  • Page 34 Operators Manual ALS 230 Power On at power on at power on at power on CODE CODE Standard menu Extended menu Product menu Configuration INIT/ON/OFF INIT/ON/OFF INIT/ON/OFF Direct LPIT PD01 DTST INIT/ON/OFF CONT PD02 P_S_ SENS PD03 MACH STOD STOD...

  • Page 35: Standard Menu

    Operators Manual ALS 230 5.1 Standard menu Usually this menu is used for labelling. All important parameters can be changed while the machine is running. After turning power on, the standard menu is active, unless the product menu was on before the machine was switched off.
  • Page 36 Operators Manual ALS 230 Label position ____________________________________________________POS Function: The start position POS defines when the labelling should take place, after the product has passed the product sensor. Changing the value for POS changes the applied label position on the product.

  • Page 37: Extended Standard Menu

    Operators Manual ALS 230 5.2 Extended standard menu The extended standard menu offers additional parameters you may use in your application. On quitting this menu the current parameter settings are stored in memory. Further changes are also written into memory. As long as this menu is active, no labelling is possible. By pressing the key FEED, however, single dispense of labels is possible.
  • Page 38 Operators Manual ALS 230 Display Function Data value APT3 Restart delay 0 ... 5000 ms APT4 Time constant compensation 0 ... 500 ms ASTP End of air stream signal -20 ... 50 mm Printer dwell time OFF - 1000ms Printer hold time (is 50% PDT)
  • Page 39 Operators Manual ALS 230 Sensor status ____________________________________________________SENS Function: Status of label sensor is indicated, i.e. there is a label in the sensor the abbreviation LAB is displayed and GAP is shown if there is only backing material inside the label sensor.
  • Page 40 Operators Manual ALS 230 Stop position ___________________________________________________ STOD Function: Stop position of the label at the dispensing edge. Available: Always Range: 0.0 ..200.0 mm Product length ___________________________________________________PRDL Function: The product length avoids multi labelling in case of difficult products. Normally it is set to AUTO.
  • Page 41 Operators Manual ALS 230 Start delay_______________________________________________________STAD Function: Delay time for the dispensing by means of an applicator after the product has passed the product sensor. This value influences the position of the label on the product. Only available if applicator is used.
  • Page 42 Operators Manual ALS 230 Blow on time ____________________________________________________ APT2 Function: Only used when an applicator is necessary. It defines for how long the label is blown onto the product. Available only with applicator. Range: 1 ... 7500 ms Restart delay ____________________________________________________ APT3 Function: This parameter defines the time for a next label dispense after the applicator cycling is completed.

  • Page 43: Product Menu

    Operators Manual ALS 230 End of air stream signal ___________________________________________ASTP This parameter determines how long the air stream signal will remain active after the label dispense has finished. Valid in all modes (direct dispense, applicator, APSF and fixed-speed). Printer dwell time __________________________________________________ PDT This determines the dwell time of the stamp-printer.
  • Page 44 Operators Manual ALS 230 Note: If the FEED key is not pressed after loading a new product bank the first detected label edge will be moved to the dispense position at the first signal from the product sensor! Note: The function FACT available in the configuration menu clears all the product banks.
  • Page 45 Operators Manual ALS 230 Release 12/07 Page 43 Menu structure...

  • Page 47: Configuration

    Operators Manual ALS 230 6. Configuration Adjustments in the configuration menu are necessary during installation of the machine only. In the configuration menu, the required optional functions can be selected. Some service support functions in the configuration menu will be useful for the service staff.

  • Page 48: Handling The Menu

    Operators Manual ALS 230 6.1 Handling the menu The menu structure is shown in the following table. By means of the key PRIOR you switch to the prior function, and with the key NEXT to the next following function in the menu.

  • Page 49: Menu Functions

    Operators Manual ALS 230 6.2 Menu functions The menu functions are explained in detail here. Permanent test ___________________________________________________ DTST The permanent test makes a test run without using labels. In the display the numbers of dispense cycles is shown (see description LABC). Immediately after starting the function, the machine runs in a self-test.
  • Page 50 Operators Manual ALS 230 With this function, you can decide how to react: NONE Do nothing. The unlabeled product will be detected later in the line. WARN Set the warning output and displays W__0. The production continued. ERR1 Set the error output to stop the production line immediately and display E_10.
  • Page 51 Operators Manual ALS 230 Additional functions in the standard menu Depending on which parameter has been defined under APPL different menu functions are shown in the standard menu. If an applicator is used additional times BLOW and STAD for controlling the applicator cycling are available.
  • Page 52 Operators Manual ALS 230 6 = terminal 20 = ERROR 7 = terminal 31 = READY 8 = terminal 32 = ODC_OUT / HORI_CYL Adjustment resetting______________________________________________ FACT This menu point sets all parameters back to the factory values. All parameters will be reset, so please note all your adjustments before.
  • Page 53 Operators Manual ALS 230 Number of data bits _______________________________________________ DBIT The function is only visible if a baudrate is selected. With this function you can select between 7 or 8 data bit protocols. Factory adjustment: 8BIT Recycle (simulates max labels/min) ________________________________ RECY The Auto-recycle function, is used to determine the maximum possible cycle rate with the current parameter settings.
  • Page 54 Operators Manual ALS 230 Note: Modified parameter values are only stored if the menu is left by using the QUIT function. If the power is switched off before leaving the menu by quit all modifications are lost. Release 12/07 Page 52...

  • Page 55: Serial Interface

    Operators Manual ALS 230 7. Serial interface The machine has a serial interface according to the standard RS232C. Via this interface parameters can be adjusted. All received commands are tested for syntax and legal value range. Invalid commands and parameters are ignored. An error message is not given in this case.

  • Page 56: Interface Commands

    Operators Manual ALS 230 Factory interface deactivated, at reactivation the parameters will be set to 8 data bits, 2 stop bits and no parity bit. 7.2 Interface commands The below described commands will change one of the labelling parameter. The values are not stored and will be lost when turning off power.
  • Page 57 Operators Manual ALS 230 Command Description Range #!MACHnnnn Machine type 0000 ALS230 0001 ALX720 0002 ALS330 0003 ALS430 #!MDIRnnnn Motor direction 0000 Right --- > 0001 Left < --- #!MLABnnnn Missing label error 0000 NONE 0001 Warning 0002 Error 1...

  • Page 58: Bit Definition In Error Flag

    Operators Manual ALS 230 #!LABC The machine sends the number of dispensed labels e.g. LABC0000008359 back #!SP__ The machine is set to off. The product sensor is disabled and labelling will therefore be stopped. #!SR__ The machine is set to on. The product sensor is enabled and labelling can restart.

  • Page 59: Connections And Signals

    Operators Manual ALS 230 8. Connections and signals This machine has a number of inputs to connect sensor’s and a control. Outputs are available for applicators, a printer and other purposes. 8.1 Output signals This machine has eight outputs, which switch the output from open circuit to + 24V. The maximum current must not exceed 500 mA.
  • Page 60 Operators Manual ALS 230 Release 12/07 Page 58 Connections and signals...

  • Page 61: Applicator Modes

    Operators Manual ALS 230 8.2 Applicator modes The machine is able to dispense the label direct on the passing product. There is also the possibility to drive without any external control a wide range of applicators. 8.2.1 Signals for direct dispense For direct dispensing the airstream signal can be used to control a pneumatic driven dispensing edge.

  • Page 62: Control Signals For The Asa Applicator

    Operators Manual ALS 230 8.2.2 Control signals for the ASA applicator For controlling an air stream applicator the signals air- stream and blow on are necessary. The time period APT2 defines how long the blow on signal is active. After labelling the product and the time period of APT3 a new label will be dispensed on to the applicator.

  • Page 63: Signals For The Ep Applicator

    Operators Manual ALS 230 8.2.3 Signals for the EP applicator For controlling the applicator the signals air stream, cylinder valve and blow on are necessary. After a product signal has occurred the labelling cylinder valve is switched active after the delay STAD.

  • Page 64: Applicator Connector

    Operators Manual ALS 230 8.2.4 Applicator connector The applicator connection is done via a 15 pole D-sub connector common to other machines. Figure 13 Applicator connector Release 12/07 Page 62 Connections and signals...

  • Page 65: Input Signals

    Operators Manual ALS 230 8.3 Input signals This machine (dispenser) is provided with photo coupled inputs for: the product sensor signal an inhibit signal for inhibiting labelling a signal from an OD control which shows the end of the material roll.

  • Page 66: Product Sensor

    Operators Manual ALS 230 8.3.1 Product sensor The product sensor starts the labelling. The source of the signal could be a optical sensor, a switch or a signal from a PLC. The time between start signal and start of dispensing (adjusted with POS) should be as small as possible.

  • Page 67: Od Control Sensor

    Operators Manual ALS 230 8.3.2 OD Control sensor Optional an OD control could be mounted to control the label roll. If the label material is nearly empty the sensor gives an signal. A warning message and an output signal inform the personal that in the next time the material has to be changed.

  • Page 68: Apsf Sensor

    Operators Manual ALS 230 8.3.3 APSF sensor For the APSF function (Automatic speed follower) a rotary encoder has to be installed. For optimum labelling accuracy the rotary encoder should be selected so that it produces one pulse for every 0.125 mm of product movement. The connection of the encoder should be done with a shielded cable.

  • Page 69: Control Signals

    Operators Manual ALS 230 8.3.4 Control signals An optional connector could be installed for integration of the machine in the line control. Inhibit + Startunterdrückung + white weiß +24 Volt +24 Volt Inhibit - Startunterdrückung - blue blau Error output...
  • Page 70 Operators Manual ALS 230 Figure 22 Internal I/O connector Release 12/07 Page 68 Connections and signals...

  • Page 71: Emi

    Operators Manual ALS 230 8.4 EMI To protect the machines against electrical noise and to protect production of electrical noise you have to follow this rules: Rule 1 All metallic parts must have a good and plane contact (no lacquer, aluminium oxide is an isolator).

  • Page 72: Electronic Diagrams

    Operators Manual ALS 230 8.5 Electronic diagrams Figure 23 Wiring diagram Release 12/07 Page 70 Connections and signals...
  • Page 73 Operators Manual ALS 230 Figure 24 Layout dispenser electronic board Release 12/07 Page 71 Connections and signals...
  • Page 74 Operators Manual ALS 230 48VAC 48VAC Phase1A Phase1B + Direction - Direction - Clock Resolution + NC - NC Ready Collector Ready Emitter Ready LED Overtemperature 100% on LED Voltage Short circuit 25% on / 75% off Both 75% on / 25% off Figure 25 Layout stepper motor driver The jumper position has to be 800 steps.

  • Page 75: Errors And Warnings

    Operators Manual ALS 230 9. Errors and warnings The software checks during the labelling permanently, if the machine runs under normal operation. If labelling is not possible, the display shows a message e.g. E__0. If the labelling can be continued, but a problem has occurred or may occur, the display shows a warning e.g.
  • Page 76 Operators Manual ALS 230 Message Meaning How to solve E__5 10V supply voltage for label Short circuit in label sensor or cable. sensor low. Voltage regulator U14 is damaged. E__6 24V Voltage low Short circuit on an output. Total load too high i.e.

  • Page 77: Dispenser Warnings

    Operators Manual ALS 230 9.1 Dispenser warnings In case of a warning message the relevant output is switched. The signal can be used for interconnection with an external machine control. Warning W__5 activates only the special OD warn output. Message...
  • Page 78 Operators Manual ALS 230 Release 12/07 Page 76 Errors and warnings...

  • Page 79: Technical Specification

    Operators Manual ALS 230 10. Technical Specification The following data are maximum values. Depending on label material, operation environment and labelling condition the real value could be lower. 10.1 Technical Information Description Details Label width: 10 mm ... 100 mm incl.

  • Page 80: Application Specification

    Operators Manual ALS 230 Description Details Mains voltage 100V~, 115V~, 200V~ and 230V~ 50/60Hz (6.3A for 110V else 3.15A), +5%- 10% 10.2 Application specification The labeller is designed and built for automatic applies of self-adhesive labels. 10.3 APSF- Sensor Specification (Optional function) The resolution of the sensor should be selectedsuch per 1mm product movement 1 to 5 pulses are generated.

  • Page 81: Performance

    Operators Manual ALS 230 10.4 Performance The following tables show the maximal theoretically labels per minute rate. Tolerances in product speed, label and product dimensions reduce the label rate. The tables are valid for direct dispensing (without applicator and printer). For critical applications, performance test should be done first.

  • Page 82: Dispensing Speed Reached While Dispensing Certain Label Length

    Operators Manual ALS 230 10.4.2 Dispensing speed reached while dispensing certain label length Dispensing speed reached in reference to label length dispensed Label length (mm) Label length Dispensing Label length Dispensing (mm) speed reached at certain (mm) speed reached at certain...
  • Page 83 Operators Manual ALS 230 Note: As in most real labelling environments the products will have a spacing of at least 1cm the actual labelling rate can simply be calculated by dividing the product pitch into the conveyor speed. Product length = 100 mm; Product distance = 50 mm;...

  • Page 85: Adjustment

    Operators Manual ALS 230 11. Adjustment Function Factory Application P_S_ LEDG MACH MDIR RAMP FAST MLAB WARN COMP APSF APPL BAUD NONE PARI SBIT 2BIT DBIT 8BIT DIST 76.0 mm SLEW FAST Release 12/2007 Page 83 11 Adjustment...
  • Page 86 Operators Manual ALS 230 Function Factory PD01 PD02 PD03 PD04 POS(STAD) 100.0 mm VELO 30.0 m/min STOD 76.0 mm BLOW(APT2) 1 ms LPIT AUTO CONT AUTO PRDL AUTO EGRA APT1 200 ms APT3 0 ms APOS ASTP Function PD05 PD06...

  • Page 87: Index

    12. Index Labelling position ........49 applicator ........... 53, 55 Applicator..........42 MACH ......Siehe Machine type APSF ........... 40, 42, 58 Machine type..........41 ASA............53 missing label ..........41 Automatic product speed follower..Siehe APSF OD control..........57 OD-Control..........

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