USER MANUAL Label Dispenser ALS 306 309 Edition 05 (10/08)
ALS 306 309 GB CONTENTS 1 Please note 1.1 General notes 2.1.5 Technical specifications . . . . . . . . . . . . . . . . 17 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . .17 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Label sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Interfaces. . . . . . . . . . .
ALS 306 309 GB CONTENTS 3 Before operation 3.1 Electrical connections 4.3 4.3.1 What are product profiles? . . . . . . . . . . . . . . 50 4.3.2 Loading a product profile . . . . . . . . . . . . . . . 50 3.1.1 Power supply connection . . . . . . . . . . . . . . . 32 Connecting the power cable . . . . . . . . . . . . . . . 32 Disconnecting the power cable . . . . . . . . . . . . . 32 4.3.3 Storing a product profile . . . . . . . . . . . . . . . . 50 Selecting the memory location . . . . . . . . . . .
1 ALS 306 309 GB PLEASE NOTE 1.1 GENERAL NOTES 1 P LE AS E NO T E 1.1 GENERAL NOTES 1.1.1 Validity and binding effect of this manual Contents Copyright The present manual refers exclusively to the ALS 30x label dispensers. It is written for the purpose of ensuring professional usage and calibration of the unit. Avery Dennison holds all rights to this manual and its appendices.
1 ALS 306 309 GB PLEASE NOTE 1.1 GENERAL NOTES 1.1.2 Illustrations and descriptions Signs and symbols Figures Various information types are indicated in different ways within the document in order to simplify readability and comprehension. Texts are accompanied by figures where necessary. Figures are indicated using figure numbers in [square brackets]. A capital letter after a figure number, for example [12A], refers to a specific section of the figure.
1 ALS 306 309 GB PLEASE NOTE 1.2 SAFETY INSTRUCTIONS 1.2 SAFETY INSTRUCTIONS 1.2.1 Information and qualifications Ensure the required qualifications are met Follow the instructions £ Ensure that only trained and authorized personnel operate, configure and service the unit. £ Only allow qualified and well-trained expert personnel or service technicians to perform configurations.
1 ALS 306 309 GB PLEASE NOTE 1.2 SAFETY INSTRUCTIONS 1.2.2 Operational safety of the unit £ Only link the unit to devices that fulfil the SELV (safety extra-low voltage) circuit requirements specified in EN 60950. £ Make sure that the power switch at the machine is accessible. £ In case of emergency, switch off the device. Proper usage The label dispenser is a fully automatic unit for attaching self-adhesive labels to products or packaging.
1 ALS 306 309 GB PLEASE NOTE 1.2 SAFETY 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. £ Keep moving parts free from obstructions even when the unit is not switched on, if there is a chance the machine might be turned on. £ Switch off the machine before making any mechanical settings.
1 ALS 306 309 GB PLEASE NOTE 1.2 SAFETY INSTRUCTIONS 1.2.3 Before beginning production Due diligence of the operating company and the service technician Due diligence of the user £ Check that the safety installations are working properly. £ Inspect the machinery for any visible damage. Report any ascertained defects immediately. £ Use the required personal protective equipment correctly, for example, wear a hairnet. £ Remove any unnecessary materials and objects from the operating area of the unit.
1 ALS 306 309 GB PLEASE NOTE 1.2 SAFETY INSTRUCTIONS 1.2.4 Safety notes on the unit CAUTION! Warning notes on the unit represent important information for the personnel using it. £ Do not remove warning notes. £ Replace any missing or illegible warnings. The ‘Pinch Point’ warning [1A] note warns you of the danger posed by the machine’s rotating parts; they can trap items and draw them in. The blue label ‘Read manual’ [1B] demands that users read the unit instructions. ! WARNING A Pinch point.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW 2 2.1 P R O DU C T D E SC R IPT IO N OVERVIEW 2.1.1 Components A B C O D E F N M J L G K H I [2] ALS 306 Label Dispenser (right-handed version).
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW I Dispensing edge – Pictured: fixed L-shape dispensing edge. – Optional available are: swivelling L-shape dispensing edge, spring-loaded L-shape dispensing edge, pneumatic L-shape dispensing edge. A Dancer arm – Keeps the label material stretched tight evenly. – Arrests the rotation of the material roll if tension diminishes. B Unwinder – Spread core mandrel grasps the label roll.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW 2.1.2 Control panel A B Operating LED Lights up green when the device is switched on. C Error LED D Lights up red when an error occurs. ON STATUS Online Labels 292 – + – + LCD display [3] – Displays functions, configured values, operating states and error messages. – What is displayed at any one time depends on the operating status of the device; these screens are explained in the section “Operating modes” on page 24.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW 2.1.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW 2.1.4 Mode of operation In labelling mode, the label web is first pulled from the label roll around the dancer arm [5A], which consistently maintains even tension in the label web. The feed rollers [5D] in front of and behind the dispensing edge [5C] draw the label web across the dispensing plate. The label is peeled from the backing paper on the dispensing plate and is pressed onto the product by the pressure roller [5B].
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW 2.1.5 Technical specifications Characteristics Label sensor Dispensing speed 1): ALS 306 ALS 309 Distance to peel edge max. 60 m/min max. 45 m/min L-shape dispensing edge: Labelling halt precision at the peeling edge: Variable speed: Constant speed: Transmission sensor: < ±1 mm < ±0.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW Environmental conditions Operating temperature: 5 to 40°C Humidity: 30 to 85%, (non-condensing) Noise (at a distance of 1 m): 72 dB(A) Protection class: IP 21 Certificates – CE, TÜV/GS, FCC, CCC, GOST, NRTL, US/CA – The regulation DIN EN 55022 demands for class A devices the following text to be printed in the manual: „WARNING: This is a class A product.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.1 OVERVIEW 2.1.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.2 OPTIONS 2.2 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. [9] External control panel Fixed dispensing edge – The dispensing edge has a fixed connection to the brackets. – To adjust the vertical position, lift/lower the entire device.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.2 OPTIONS 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 Outer diameter control sensor The outer diameter control sensor (OD sensor) triggers a warning, if the label roll outer diameter falls below a certain, adjustable value.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.2 OPTIONS Additional material guide disk The additional material guide disk [16]A] improves the lateral guiding of the material roll. This option is especially recommended, if very narrow material (< 30 mm width) is processed. A [16] Additional material guide disk (A) Capacitive label sensor Optional sensor, required for processing transparent labels [17]. The sensor is mounted to the rods of the dispensing edge holder.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.3 OPERATING MODES 2.3 OPERATING MODES 2.3.1 Dispensing mode This is the operating mode of the unit when switched on. You can carry out the functions listed in the sections below. ON STATUS Online If text such as ‘Prof 5 xxxxxxxx’ is displayed instead of ‘ONLINE’: – The ‘xxxxxxxx’ product profile (memory location 5) is activated. – For more information, see the ‘Using product profiles’ section.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.3 OPERATING MODES Online settings A B C The machine is in dispensing mode. ON STATUS To switch to the online settings mode: £ Press the button. Offset 0.0 Speed 12.2 fix – The display shows the dispensing speed [19A] and the start offset [19C]. – The button assignments are as shown on the buttons. – You can increase (‘+’ button) or lower (‘–’ button) both settings in the dispensing mode [19D]. – + – + Dispensing speed: – Setting range: [2.0…60.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.3 OPERATING MODES 2.3.2 Configuration mode A The machine is in dispensing mode. ON STATUS Switching to configuration mode: £ Press the button twice. – Display: OFFLINE OFFLINE £ Press the – Display: – + – + button. B LABEL SETUP LABEL SETUP – LABEL SETUP is the name of the first menu that is currently active. – In configuration mode, the button assignments are as shown below the buttons.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.3 OPERATING MODES Functions MACHINE SETUP Every submenu contains functions for setting the unit controls. Figure [21] shows the button functions for changing settings using the MACHINE SETUP > Language function as an example. MACHINE SETUP Store Prod.Prof. 15x MACHINE SETUP Language Language English A B Language German [21] Button functions for setting the MACHINE SETUP > Language function.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.4 FUNCTION DESCRIPTIONS 2.4 FUNCTION DESCRIPTIONS 2.4.1 Overview of functions SIGNAL INTERFACE APPLICATOR PARA 9) LABEL SETUP MACHINE SETUP INTERFACE PARA Load prod.profil Store prod.prof. > EASYPLUGINTERPR Interface mode Operation enable Gap detect mode Del. prod.profil Interface > PLC INTERFACE Applicator type Dispense speed Dispense counter Spooler mode End dispense mod Apply mode Slew speed Factory settings Dispenser ID no. Disp.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.4 FUNCTION DESCRIPTIONS SERVICE/DIAGNOS. SERVICE DATA (continued) Sensor Test > MODULE FW VERS. > DISPLAY DATA Compactflashtest System version Display version Test functions System revision Display serial # Diagnosis to CF System date Remote disp. vers. 2) Bootloader Remote disp. # 2) uMon Applicator int. 1) > CF CARD SLOT Card in slot > OPERATION DATA Serv. operations > MEMORY DATA Tot. mat. length Ram memory size Dispensing cycl.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.4 FUNCTION DESCRIPTIONS 2.4.2 Notes on function descriptions Label pitch function: – Label pitch = label length+space – Setting range: [5.0…600.0] mm – See chap. “Label pitch” on page 45 The following chapters only describe those functions that are necessary for operating an ALS 30x that has been configured and set up. These functions are highlighted in grey in the overview. Lab.
2 ALS 306 309 GB PRODUCT DESCRIPTION 2.4 FUNCTION DESCRIPTIONS Turn-on mode function: – The operating mode of the unit after it is turned on. – Settings: [Online, Offline] Online: Dispensing mode Offline: Configuration mode Miss. label tol. function: – Missing label tolerance – The maximum permissible number of successive missing labels on the label strip – Setting range: [0…10] mm; default: 1 – See chap.
3 ALS 306 309 GB BEFORE OPERATION 3.1 ELECTRICAL CONNECTIONS 3 3.1 B E FO R E O PE R AT IO N ELECTRICAL CONNECTIONS 3.1.1 Power supply connection WARNING! This machine operates using mains voltage! Touching live electrical parts may expose you to hazardous electrical currents and may lead to burns. A £ Make sure that the machine is switched off before you connect the power cable. £ The mains connection of the machine may only be done by authorised specialists, who are aware of the risks involved.
3 ALS 306 309 GB BEFORE OPERATION 3.1 ELECTRICAL CONNECTIONS 3.1.2 Connecting sensors A £ Check whether the required sensors are connected before turning on the unit [27].
3 ALS 306 309 GB BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL 3.2 INSERTING LABEL MATERIAL 3.2.1 Prerequisites – The label dispenser is turned off at the main switch [29A] (switch set to ‘O’). £ Check that the safety installations are working properly. £ Inspect the machinery for any visible damage. Report any defects immediately. £ Remove any unnecessary materials and objects from the operating area of the unit. £ Make sure that only authorised persons are within the operating range of the machine.
3 ALS 306 309 GB BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL 3.2.2 Inserting a label roll WARNING! Risk of injury due to moving and rapidly rotating parts! £ Before inserting the label roll, ensure that the device is turned off at the main switch. £ Do not under any circumstances turn the device on before the label web is threaded in completely. Removing spent backing paper Assuming backing paper has gathered on the rewinder [30A] : £ Press the release button [30B].
3 BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL 3.2.3 Threading diagrams [32] Threading guide for ALS 30x (dotted line = roll with labels facing inwards).
3 BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL A [33] Threading guide for ALS 30x with a 45° rotated dispensing edge (dotted line = roll with labels facing inwards).
3 BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL A B [34] Threading guide for ALS 30x with a 90° rotated dispensing edge (dotted line = roll with labels facing inwards). For use with a swivelling angle 1) of 30° or more, additional deviation rollers must be installed: – Long dispensing edge holder: 2 rollers [33A, B] – Short dispensing edge holder: 1 roller [32A] 1) 0°: Dispensing edge holder shows vertically downwards with the machine mounted in horizontally.
3 ALS 306 309 GB BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL Threading the label web at the dispensing edge Fixed [35] and swivelling L-shape dispensing edges: £ Unroll 2.5 m of label web and remove the labels from it. £ Pass the backing paper around the first deflection roller [35A] and through the slot in the sensor [35B]. £ Feed the backing paper under the pressure roller [35C] to the dispensing plate [35D]. £ Feed the backing paper around the dispensing plate to the second deflection roller [35E].
3 ALS 306 309 GB BEFORE OPERATION 3.2 INSERTING LABEL MATERIAL Threading the label web onto the drive roller B £ Open the pressure roller. To do so, rotate the lever [38A] in a clockwise direction. £ Feed the backing paper around the deflection rollers [38B] and the drive roller [38C]. £ Close the pressure roller. To do so, rotate the lever [39], until it snaps in noticeably. A C B [38] Open the pressure roller. Threading the label web to the rewinder [39] Close the pressure roller.
3 ALS 306 309 GB BEFORE OPERATION 3.3 MECHANICAL SETTINGS 3.3 MECHANICAL SETTINGS 3.3.1 Adjusting the unwinder’s core diameter B Tool: – 3 mm hexagon (Allen) screwdriver B The unwinder can be adjusted with core adapters [42A] to fit the inner diameter of the label roll. The adapters must be fitted and dismantled in different ways depending on this diameter: – 38.1 mm (1”) core £ Unscrew the screws [42B] (2 for each adapter) and remove the adapters.
3 ALS 306 309 GB BEFORE OPERATION 3.3 MECHANICAL SETTINGS 3.3.3 Positioning the label sensor £ Release the thumb screw. £ Position the sensor along the axle in such a way as to allow it to register the spaces between the labels. B The LED [45A] lights up when the sensor is positioned over a label. A [45] Label sensor from Wenglor, model OPT242-P800 3.3.
4 ALS 306 309 GB OPERATION 4.1 START-UP AND SHUTDOWN 4 4.1 O P E RA TIO N START-UP AND SHUTDOWN 4.1.1 Turning on the unit £ Set the main switch [48A] of the unit to ‘I’ (On). – The following messages are displayed during the start process: A ALS306 RH: V 1.
4 ALS 306 309 GB OPERATION 4.1 START-UP AND SHUTDOWN 4.1.3 Stopping the dispensing process – The machine is in dispensing mode: £ Press the button. – Display: ONLINE Stopped: xxx – The dispenser stops.
4 ALS 306 309 GB OPERATION 4.2 CONFIGURATION AND MONITORING 4.2 CONFIGURATION AND MONITORING 4.2.1 Function menu settings Label pitch A £ Switch to configuration mode B 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 [49C]. £ Call the LABEL SETUP > Label pitch function. £ Enter the measured value in millimetres.
4 ALS 306 309 GB OPERATION 4.2 CONFIGURATION 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. Configuring a fixed value: £ Use the two left buttons to set the speed in dispensing mode (online settings) (see “Online settings” on page 25).
4 ALS 306 309 GB OPERATION 4.2 CONFIGURATION 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” on page 25). Or use the function menu settings: £ Call the LABEL SETUP > Start Offset function and set the start offset.
4 ALS 306 309 GB OPERATION 4.2 CONFIGURATION AND MONITORING 4.2.2 Monitoring functions While in dispensing mode, an electronic controller monitors the following functions: Material end / Roll diameter (OD = outer diameter) To enable a quick renewal of the material roll, the machine can alarm the operator before the end of the material roll is reached.
4 OPERATION 4.2 CONFIGURATION 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 35). Missing labels A label missing from the label roll does not normally affect the dispensing operation, because the label feed continues until a label’s edge passes under the label sensor. Nonetheless, it can be important that missing labels are reported.
4 ALS 306 309 GB OPERATION 4.3 USING PRODUCT PROFILES 4.3 USING PRODUCT PROFILES 4.3.1 What are product profiles? 4.3.3 Storing a product profile Product profiles are memory locations that can store all the settings for the machine controls. For recurring production jobs, they allow you to quickly set the machine to the respective product. Selecting the memory location £ Call the MACHINE SETUP > Store prod.prof. function.
4 ALS 306 309 GB OPERATION 4.3 USING PRODUCT PROFILES – The profile is saved. – Display: Store prod.prof. Storing… – The product profile has now been saved. 4.3.4 Deleting a product profile £ Call the MACHINE SETUP > Del. prod.profil function. – The memory location that was active last is displayed. £ Press the or the button until you retrieve the memory location you require (1–16). £ Press the button to delete the memory location: – Display: Del prod.
5 AFTER OPERATION 5.1 MAINTENANCE AND CLEANING 5 A FT ER O P ER A TIO N 5.1 MAINTENANCE AND CLEANING 5.1.1 Cleaning agents Cleaning agents for rubber rollers: – Roller cleaner, order number 98925. If other cleaning agents are used, there is a chance the rubber may corrode.
5 ALS 306 309 GB AFTER OPERATION 5.1 MAINTENANCE AND CLEANING 5.1.2 Regular maintenance 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. £ Clean the sensor lenses with a soft brush or cloth.
6 ALS 306 309 GB OPERATIONAL FAILURES 6.1 STATUS MESSAGES 6 6.1 O PE R AT IO N AL FA IL UR E S STATUS MESSAGES 6.1.1 Types of status messages 6.1.2 List of warnings Error messages When an error occurs, the machine stops immediately and displays an error message on the control panel. Displayed text Meaning Produktstartwarn New start signal during the dispensing operation.
6 ALS 306 309 GB OPERATIONAL FAILURES 6.1 STATUS MESSAGES 6.1.3 List of error messages Status Status text 5000 Bus device Cause Action to take 2 £ Delete the message by pressing the – Device at I C Bus cannot be -key. contacted. – In most cases, this message appears £ Switch the machine off, wait 30 seconds and switch it back on. as the first in a series of two or three £ If the error message appears messages which narrow down the error more precisely. repeatedly, call in a servicing technician.
6 ALS 306 309 GB OPERATIONAL FAILURES 6.1 STATUS MESSAGES Status Status text Cause Action to take 5140 Rewinder control £ Press the key. – This reinitialises the dancer arm control; the dancer arm moves back into the control position. Rewinder control During problem-free operation, the rewind unit dancer arm only moves a minimal distance around the "control position". This is the position the dancer arm takes up after initialisation of the machine.
6 ALS 306 309 GB OPERATIONAL FAILURES 6.1 STATUS MESSAGES Status Status text 5147 Tandemsynch. Init Cause Action to take This message can only appear during tandem operation. – Communication between the master and slave machines is not functioning. 5200 Home position £ Check, if the slave machine had been switched on before the master machine - if not, repeat the switching on in the correct order (first slave, then master).
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