Operators Manual ALS 230 Contents 1. Important Notes........................................................................................................ 4 1.1 Overview....................................................................................................................................... 4 1.1.1 Manufacturer...................................................................................................................... 4 1.1.2 Copyright................................................
Operators Manual ALS 230 4. Operation ............................................................................................................... 23 4.1 Safety recommendation ..............................................................................................................23 4.2 Inserting label material................................................................................................................24 4.3 Initialise new label material ..........................................
Operators Manual ALS 230 8.4 EMI ............................................................................................................................................. 66 8.5 Electronic diagrams .................................................................................................................... 67 9. Errors and warnings ............................................................................................... 71 9.1 Dispenser error messages .....................................
Operators Manual ALS 230 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. Except for cleaning the rollers and the label sensor there is no periodical maintenance necessary. This manual should help you to operate the ALS 230.
Operators Manual ALS 230 Avery Dennison Corporation is given or implied. All other brand and product names are the trademark of their respective owners. 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. The necessity for this has to be decided on case by case. See also regulation EN 292 and 294. 1.2.
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. The safety of the machine, however, can only be put into operating practice if all measures required for the safety are taken.
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.
Operators Manual ALS 230 1.2.
Operators Manual ALS 230 1.2.
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. 2.1 Mechanics The machine is available in a right- or a left-hand version. The expression right or left is related to the direction of product transport. In the following, a right hand machine is explained.
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. Drive roller (001) keeps the transport speed of the material constant. Deviator rollers (012) guide the backing material around the drive roller (001).
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. Except for the drive roller (001) and the material brush (006) the labeller has no wearing parts. The operator panel (019) is described in the next chapter.
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. NEXT: This key moves down the menu (next function) or decreases the value of a parameter. If the down arrow key is pressed and held as the machine is turned on the standard menu is selected. ENTER: This key is used to enter or exit a menu point or to cancel a warning or error message.
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. The connection of the other plugs is described in chapter Connections. If you use the optional connections, it is strongly recommended to do this by means of the optional available SUB-D connectors. This ensures best EMI stability of the machine.
Operators Manual ALS 230 Release 11/05 Page 16 Description
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. 1.1 Installation 1.1.1 Unpacking of the unit • • • • For removing the unit off the box, don’t hold the machine on the dispensing edge to prevent disadjustment off the machine.
Operators Manual ALS 230 1.2 Prepare dispensing 1.2.1 Insert material Insert your label material in the machine to follow the instructions in the chapter Operation / Threading. 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. There are some reasons the automatic initialisation is not possible: 1.
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 edge of label Sensor signals Figure 4 Definition of LPIT All other label edges seen by the label sensor will be ignored until the distance adjusted in the "LPIT" parameter has been fed through the label sensor.
Operators Manual ALS 230 A mechanical sensor is limited in the speed. The bounce at the label edges produces wrong signals. There is optional a capacitive label sensor available (Leuze GK14/24L). Adjustment of the sensor is carried out as follows (Figure 5): 1. Set sensitivity to maximum by turning the Potentiometer clockwise. Then rotate ½ turn anticlockwise. 2. Remove label material out of sensor. 3. Perform base adjustment, that both LED “base adjustment” have the same brightness. 4.
Operators Manual ALS 230 With a L-dispensing the adjustment is done by move the tail sheaves behind the dispensing edge. 3.3 Adjust dispense function For an operation without any trouble and high label accuracy, tree adjustments are required: • Label position on the dispensing edge: stop position • Dispense speed • Label position on the product The adjustment should be done in the same order, because parameter like the stop position depends on the setting of the stop position and the dispensing speed. 3.
Operators Manual ALS 230 3.3.3 Automatic dispensing speed (APSF) With a connected rotary encoder, the dispensing speed follows the measured product speed. To adjust the speed use the EGRA function located in the extended standard menu. The measured speed will be displayed in the VELO function. Do the adjustment in the same way described for fixed speed. 3.3.
Operators Manual ALS 230 4. Operation This chapter describes the operation of the machine. 4.1 Safety recommendation CAUTION! y y y y y 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. Handling of the machine is permitted only trained personal. Be careful on operation, fingers, hair, clothes, jewellery, etc. may be caught by and get into rotating axles.
Operators Manual ALS 230 4.2 Inserting label material Attention: • Before threading the new material, the waste paper should be removed. CAUTION! - Isertion/exchange of material should be carried out only by especially instructed personal. Threading of the label material is shown down below on the threading diagrams for the right-hand and the left-hand version.
Operators Manual ALS 230 4.3 Initialise new label material The machine requires data of the label material in use i.e. label length and opacity of the label and backing material. In most cases, those parameters can be scanned during automatic initialisation. This is not always possible. During initialisation, the machine uses its label sensor to determine where the labels are on the label web and the distance between the leading edge of labels (the label pitch) so that they can be positioned correctly.
Operators Manual ALS 230 4.4 Control of dispense unit 4.4.1 Dispenser Menu selection Turning on the mains switch and at the same time pressing one of the panel keys, you may select between several options: PANEL KEY & mains switch Function Display message FEED Material initialisation INIT NEXT FUNCTION Standard menu ON PRIOR FUNCTION Product menu PD0n ENTER Configuration menu CODE Press the key as long as the display shows the version number.
Operators Manual ALS 230 y Error display: If the display shows e.g. E__XX, the dispenser has recognised an error. A warning is shown by W_XX. As soon as the error has been corrected, you may erase the message by pressing the key ENTER and you will get back to the status the machine was in before the error was indicated. Note: Data entered in the standard menu are not stored, if the machine is switched off. If you need to store data you have to use the extended menu.
Operators Manual ALS 230 pressing the key PRIOR the value is increased, i.e. the label is put on later. By pressing the key NEXT FUNCTION the value is decreased and the label is put on earlier. The labelling position is also changed by variation of the product speed. In this case first control you product speed and the dispense speed VELO. Only if both speed matches adjust the position with the POS function.
Operators Manual ALS 230 Figure 9 Stop position Dispense speed __________________________________________________VELO The speed value VELO displays the dispensing speed in 0.1 m/min. The product conveyor speed has to be constant to assure accurate labelling. A change of the product speed causes a different position of the label on the product. In case of inaccurate labelling, it should be verified, if the speed of the dispenser and your product match together.
Operators Manual ALS 230 If you want to switch to another product, select the respective product number by pressing NEXT and PRIOR, then press ENTER. Now the new product data are activated. To change the labelling parameters you can call the extended menu. After leaving this menu, your product data will be automatically updated. The labeller carries out the labelling of your products completely automatically.
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. There are 2 levels for parameter adjustments. The first one is for parameter selection. With the keys FUNCTION a parameter is selected. By pressing the keys ENTER the second level can be reached.
Operators Manual ALS 230 • Power On CODE Extended menu INIT/ON/OFF Product menu INIT/ON/OFF at power on + or CODE Configuration INIT/ON/OFF LPIT PD01 DTST INIT/ON/OFF CONT PD02 P_S_ POS SENS PD03 MACH STOD STOD PD04 MDIR VELO PRDL PD05 MLAB + at power on Standard menu Ô Direct Applicator at power on POS PD06 APSF Ô STAD PD07 APPL INIT/ON/OFF VELO PD08 I_CH STAD STST PD09 O_CH BLOW SLEW PD10 FACT BAUD ! EGRA PD11 Ô APT1 PD12 PARI Ô APT2 PD13
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. If the product menu is active and you want to use the standard menu, switch off the machine again. Press the key NEXT FUNCTION while switching on the machine and the standard menu is active.
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. Only available if no applicator is used. Range: up to 999.9 mm in steps of 0.1 mm.
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. To get into the extended standard menu a password CODE has to be entered. The display shows the first menu point.
Operators Manual ALS 230 Display Function Data value PDT Printer dwell time OFF - 1000ms Printer hold time (is 50% PDT) SAVE Store data in the product data bank PD01 ... PD09 LOAD Load data from a product data bank PD01 ... PD09 QUIT Leave the extended standard menu standard menu Label pitch _______________________________________________________LPIT Distance between 2 labels on the label web, measured from leading edge to leading edge.
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. This means that the product length is set to the label length.
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. Range: 1 to 9999 ms Dispensing speed ________________________________________________VELO Function: The labelling speed may be adjusted with the parameter VELO. Values between 0.2 and 30.
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. Available only with applicator. Range: 0 ...
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. A new dispense is prevented after PDT expires for a time equal to 50% of PDT.
Operators Manual ALS 230 5.3 Product menu If parameters have to be changed because of different products and labels, the product menu can be used. The machine offers a data bank in which 14 sets of data can be stored. If you want to switch to a particular product, select one of the product numbers by pressing NEXT or PRIOR and confirm with ENTER .The new parameters are valid now.
Operators Manual ALS 230 Release 11/05 Page 42 Menu structure
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.
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. If you press the key ENTER the current parameter value of a function is shown. The current parameter value can be changed with the keys PRIOR FUNCTION or NEXT FUNCTION. Values are stored by pressing the key ENTER.
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. The test run works with all adjusted parameters. The test can be stopped by pressing the key ENTER.
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. ERR2 The first unlabeled product generates the warning. Two unlabeled products in a sequence set the error. ERR3 The error condition will be set at 3 unlabeled products.
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. Input and sensor check____________________________________________ I_CH To display the status of sensor’s and inputs information are grouped in 3 blocks you can select by pressing the NEXT or PRIOR keys.
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. When you call this function the display shows 'NO`. After you have left by pressing the key ENTER there is no change.
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.
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.
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. All commands received over the serial interface are tested for syntax and range; invalid commands and out of range parameter values are ignored. A warning message is not given in these cases.
Operators Manual ALS 230 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. If the sequence nnnn is replaced by the character "?" then the current value of that parameter will be returned by the labelling machine as a 4 character string confirming the name of the parameter requested followed by 4 numbers representing the current value of that parameter.
Operators Manual ALS 230 Command #!MDIRnnnn Description Motor direction Range 0000 Right --- > 0001 Left < --- #!MLABnnnn Missing label error 0000 NONE 0001 Warning 0002 Error 1 0003 Error 2 #!PDT nnnn Print dwell time 0001 – 1000 ms 0000 printer off #!PHT nnnn Printer hold time 0001 – 7500 ms #!POS_nnn Labelling position 0001 – 9999 * 0.
Operators Manual ALS 230 #!SR__ The machine is set to on. The product sensor is enabled and labelling can restart. For a full automatic operation, the following procedure in case of an error is required: • #!ERRF Request error • #!CLRE Clear error message after fixing the error.
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. The four signals for error messages, machine ready, low material and warnings are available for other machines in the process or additional alarm signals.
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. The start of the airstream signal (= motor run signal) could be behind the start of the dispense motor, adjusted with the function APT3.
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. After that the machine is ready for a new labelling.
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. However if at this time the applicator is not in the home position then error message E__2 is generated. After the delay time APT1 the blow on valve is switched active for the time APT2.
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.
Operators Manual ALS 230 8.3 Input signals This machine (dispenser) is provided with photo coupled inputs for: y y y y y y the product sensor signal an inhibit signal for inhibiting labelling a signal from an OD control which shows the end of the material roll.
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. This means that an optical sensor should be placed 10 to 20 mm before the dispensing edge. The minimum distance is necessary for the internal speed compensation.
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.
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. For correct operation the rise and fall time of the encoder signal should be 1 µs.
Operators Manual ALS 230 8.3.4 Control signals An optional connector could be installed for integration of the machine in the line control.
Operators Manual ALS 230 l Figure 22 Internal I/O connector Release 11/05 Page 65 Connections and signals
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). Use scratch washers. Rule 2 Signal lines (Data- , communication- and control cable) has to separated to power cables. The minimum distance is 50 cm (20 cm inside a cabinet).
Operators Manual ALS 230 8.
Operators Manual ALS 230 Figure 24 Layout dispenser electronic board Release 11/05 Page 68 Connections and signals
Operators Manual ALS 230 48VAC 48VAC Phase1A Phase1B + Direction - Direction - Clock + NC - NC Ready Collector 800 Resolution 400 Ready Emitter Ready LED LED Voltage Overtemperature 100% on 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.
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. W__1. By pressing the key ENTER the message will be erased. In case of an error or warning message, the relevant output is switched.
Operators Manual ALS 230 Message Meaning How to solve E__6 to the factory adjustment. Check sum of the labelling data is wrong. Labelling Parameters are set to the factory adjustment. 10V supply voltage for label sensor low.
Operators Manual ALS 230 9.2 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 Meaning How to solve W__0 New start signal from product sensor while ALX720 is dispensing a label Multiple signals from the same product Several missing labels on the web, which can not be compensated Slow down conveyor speed or product sequence.
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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. Backing paper Label length 5 to 999 mm Diameter label roll max. 300 mm Core diameter (of label roll) 37mm (1.5”) or optional 74mm (3”) Dispensing speed 0.2- 30 m/min Material transport 0.
Operators Manual ALS 230 Description Details Power consumption 300 VA 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. It is possible to use one common sensor for several dispensers.
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. The charts are valid for software version V5.x. 10.4.
Operators Manual ALS 230 10.4.
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.
Operators Manual ALS 230 11. Adjustment Function P_S_ MACH MDIR RAMP MLAB COMP APSF APPL BAUD PARI SBIT DBIT DIST PHT SLEW Factory LEDG 230 Å FAST WARN ON OFF DIR NONE NO 2BIT 8BIT 76.
Operators Manual ALS 230 Function POS(STAD) VELO STOD BLOW(APT2) LPIT CONT PRDL EGRA APT1 APT3 APOS ASTP PDT Factory 100.0 mm 30.0 m/min 76.
12. Index A applicator ........................................... 53, 55 Applicator................................................. 42 APSF ........................................... 40, 42, 58 ASA.......................................................... 53 Automatic product speed follower....... Siehe APSF C capacitve label ......................................... 16 configuration menu .................................. 39 Configuration menu ................................. 27 D Direction...........
