OPERATING MANUAL Label Dispenser ALS 380 Article number: A6392, Release 06.
ALS 380 CONTENTS C ON TE N TS 1 Please observe the following 1.1 General information . . . . . . . . . . . . . . 4 2.1.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 13 Top-labeller right-hand version . . . . . . . . . . . . .13 Side-labeller right-hand version . . . . . . . . . . . . .13 Top-labeller left-hand version . . . . . . . . . . . . . .14 Side-labeller left-hand version . . . . . . . . . . . . . .14 1.1.1 Validity and applicability of this manual . . . . . 4 Contents . . . .
ALS 380 CONTENTS 3.2 Mechanical settings . . . . . . . . . . . . . 27 4.3 3.2.1 Setting the ribbon guides . . . . . . . . . . . . . . . 27 Operator panel support . . . . . . . . . . . . . . . . . . . 27 Deflection rollers on the rewind unit . . . . . . . . . 27 4.3.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.3.2 Loading product data banks. . . . . . . . . . . . . 48 Please observe: . . . . . . . . . . . . . . . . . . . . . . . . .
ALS 380 CONTENTS 5 After operation 4.4.19 Blowing time (APT2) . . . . . . . . . . . . . . . . . . . 66 5.1 Care and cleaning . . . . . . . . . . . . . . 73 4.4.20 Delay time (APT3). . . . . . . . . . . . . . . . . . . . . 66 5.1.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . 73 4.4.21 Fine tuning of the dwell time (APT4). . . . . . . 66 5.1.2 Regular maintenance . . . . . . . . . . . . . . . . . . 73 Remove paper waste. . . . . . . . . . . . . . . . . . . . .74 Braking brushes. . .
1 PLEASE OBSERVE THE FOLLOWING 1.1 GENERAL INFORMATION ALS 380 1 P LE AS E O BS ER V E TH E FO LLO W IN G 1.1 GENERAL INFORMATION 1.1.1 Validity and applicability of this manual Contents Copyright notice The present manual refers exclusively to the ALS 380 Labeller and the high-speed ALS 380 HS version. The manual is to be referred to for correct operation and adjustment of the machine. All rights to this operating manual are assigned to Avery Dennison.
1 PLEASE OBSERVE THE FOLLOWING 1.1 GENERAL INFORMATION ALS 380 1.1.2 Conventions and information Explanation of symbols Illustrations In order to facilitate legibility and an overview, the various types of information used herein are categorised and identified with certain symbols. When required, text passages are accompanied by illustrations. The reference to an illustration is indicated by typesetting the [illustration number] in square brackets. Capital letters following an illustration number, e.
1 ALS 380 PLEASE OBSERVE THE FOLLOWING 1.1 GENERAL INFORMATION Directional information C G Unless otherwise indicated, the directional information mentioned in the text refers to the construction of the right-hand version of Top Labeller. See Figure [1] for the explanation of directional information.
1 PLEASE OBSERVE THE FOLLOWING: 1.2 SAFETY INSTRUCTIONS 1.2 ALS 380 SAFETY INSTRUCTIONS 1.2.1 Information and qualifications Pay attention to the information Ensure necessary qualifications ➔ Only allow the machine to be operated, adjusted and serviced by instructed and authorised personnel.
1 PLEASE OBSERVE THE FOLLOWING: 1.2 SAFETY INSTRUCTIONS ALS 380 1.2.2 Machine operating safety Appropriate use Protect against injuries that can result from mechanical actions The ALS 380 labeller is a fully automatic machine for the application of self-adhesive labels to products or packages. The machine is to be equipped by the operation planners with suitable safety devices so as to protect the operating personnel from possible endangerment – e.g.
1 PLEASE OBSERVE THE FOLLOWING: 1.2 SAFETY INSTRUCTIONS ALS 380 1.2.3 Before every production start Operator's obligation and service personal to exercise care Operating personnels' obligation to exercise care ➔ Ensure the following prerequisites correspond to the information of the operating manual: – The machine is correctly installed and appropriately configured for the requirements. – All necessary safety equipment is installed. – The machine has successfully completed at least one test run.
2 ALS 380 EQUIPMENT DESCRIPTION 2.1 OVERVIEW 2 E Q UI PM E NT D ES C RI PTI O N 2.1 OVERVIEW 2.1.
2 ALS 380 EQUIPMENT DESCRIPTION 2.1 OVERVIEW 2.1.2 Principle of operation A Unwind unit – The unwinding spindle holds the label roll. – The spreader mechanism (chucking wedge) secures the label roll. In labelling mode, the unwind unit [2A] and the drive roller unit move the [2D] label ribbon. A loop is formed in the label ribbon between the pressure roller of the unwind unit [2E] and the upper braking brush [2F].
2 ALS 380 EQUIPMENT DESCRIPTION 2.1 OVERVIEW 2.1.3 Technical data Characteristic values Dispensing speed ALS 380: ALS 380 HS: 0.5 m/min to 80 m/min 0.5 m/min to 100 m/min Stop accuracy (at the dispensing edge): ± 0.5 mm Rewind unit: Spreader mechanism Label sensor: Manual or automatic setting Operation: programmable, can be set via the operator panel, The settings can be stored in 11 data banks Speed control: Automatic dispensing speed, with RPMtransmitter Dimensions max.
2 ALS 380 EQUIPMENT DESCRIPTION 2.1 OVERVIEW 2.1.4 Design versions The ALS 380 labeller is available in 4 different versions, depending on the taskat hand: Top-labeller right-hand version – Labelling from above onto the upper side of the product [3]. – The products are conveyed from left to right. – The dispensing edge is located on the right side. A B C Side-labeller right-hand version – Labelling from the side onto one of the product’s sides [4]. – The products are conveyed from left to right.
2 ALS 380 EQUIPMENT DESCRIPTION 2.1 OVERVIEW Top-labeller left-hand version – Labelling from above onto the upper side of the product [5]. – The products are conveyed from right to left. – The dispensing edge is located on the left side. Side-labeller left-hand version – Labelling from the side onto one of the product’s sides [6]. – The products are conveyed from right to left. – The dispensing edge is located on the left side.
2 ALS 380 EQUIPMENT DESCRIPTION 2.1 OVERVIEW 2.1.5 Options High-speed processing version ALS 380 HS Printer – Inkjet or heat transfer printer at the dispenser head. – Allows dispensing speeds up to 100 m/min – Available in all of the above-mentioned design versions. Applicator Serial interface If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator. Various kinds of applicators are available depending on the customer’s needs.
2 ALS 380 EQUIPMENT DESCRIPTION 2.2 OPERATOR CONTROLS 2.2 OPERATOR CONTROLS 2.2.1 Operator panel A LED indicator – Display of functions, setting values, operating states, error messages, and warning messages B If the LED indicator is ON: – The machine is in labelling mode. – Each time the product sensor is triggered, a label is dispensed. If the LED indicator is OFF: – Labelling mode is switched off. C D Keys E FEED – When this key is pressed, the machine dispenses a label.
2 ALS 380 EQUIPMENT DESCRIPTION 2.2 OPERATOR CONTROLS 2.2.2 Main switch – The main switch [8] is located to the left on the housing. – The main switch is used to switch the machine on and off. WARNING! Contact with energised components can result in life-endangering currents through the body as well as burns. Voltage continues to be present in the housing even when switched off. ➔ Only put the machine into operation when installed in a correctly installed housing.
2 ALS 380 EQUIPMENT DESCRIPTION 2.3 CONTROL SYSTEM 2.3 CONTROL SYSTEM 2.3.1 Brief description All of the machine’s functions are electronically controlled. Using the operator panel, the operators, calibration technicians, or service personnel have several options for adapting the machine's functions to current requirements. It is also possible to modify the basic machine settings. These are settings such as the motor’s direction of rotation. These settings are not to be changed in normal operation.
2 ALS 380 EQUIPMENT DESCRIPTION 2.3 CONTROL SYSTEM 2.3.
2 ALS 380 EQUIPMENT DESCRIPTION 2.3 CONTROL SYSTEM 2.3.3 Monitoring functions During labelling operation, the electronic control system and the sensors monitor the following functions. Dispensing a label to each product – A photoelectric sensor (product sensor) sends a signal when a product reaches the dispensing edge [9B]. The signal from the product sensor triggers the label feed for a single label.
3 ALS 380 PRIOR TO OPERATING 3.1 INSERT THE LABELLING MATERIAL 3 P RI O R TO O P ER A TIN G 3.1 INSERT THE LABELLING MATERIAL 3.1.1 Prerequisites – The label dispenser is switched off at the main [11A] switch. ➔ Verify flawless functioning of the safety equipment. ➔ Check machine for visible damage. Any discovered deficiency is to be reported immediately. ➔ Non-required materials and objects are to be removed from the working area of the machine.
3 ALS 380 PRIOR TO OPERATING 3.1 INSERT THE LABELLING MATERIAL Insert new label roll Only top-labeller: ➔ Loosen the set-screw at the guiding rod [13C] and swing the guiding rod to the side. All design versions: ➔ Rotate the knurled knob [13B] clockwise, to retract the chucking wedge [13A] in the unwinding spindle. ➔ If there is still an old roll core on the unwinding spindle: remove the old roll core. ➔ Completely push on the new label roll.
3 ALS 380 PRIOR TO OPERATING 3.1 INSERT THE LABELLING MATERIAL 3.1.
3 ALS 380 PRIOR TO OPERATING 3.1 INSERT THE LABELLING MATERIAL Thread the label ribbon at the unwind unit. B ➔ Swing up the pressure roller [16B] and the braking brush [16C]. ➔ Thread the label ribbon around the deflection roller [16E], dancer armroller [16A] and drive roller unit [16D]. ➔ Form a loop after the drive roller unit and guide the label ribbon over the operator panel support [16F]. ➔ Swing the pressure roller and web brake back into position.
3 ALS 380 PRIOR TO OPERATING 3.1 INSERT THE LABELLING MATERIAL Thread in the label ribbon at the dispensing edge. ➔ Swing up the pressure roller [17D] behind the dispensing edge. ➔ Unthread approximately 2 m of label ribbon from the label roll. ➔ Guide the label ribbon around the first deflection roller [17A] and through the slot in the photoelectric sensor [17B] for the dispensing edge. ➔ Guide the label ribbon around the dispensing edge to the drive roller unit [17C].
3 ALS 380 PRIOR TO OPERATING 3.1 INSERT THE LABELLING MATERIAL Thread the label ribbon at the rewind unit. ➔ Thread the label ribbon around the deflection rollers and the dancer armrollers as shown in figure [18]. ➔ Open the spreader mechanism of the rewinding roller using the lever [18C]. – When the spreader mechanism is open, the red point on the rewinding roller is visible. ➔ Insert the end of the label ribbon into the slot on the rewinding roller.
3 ALS 380 PRIOR TO OPERATING 3.2 MECHANICAL SETTINGS 3.2 MECHANICAL SETTINGS WARNING! Risk of injury due to moving or rapidly rotating parts! ➔ Before carrying out the mechanical settings, ensure that the machine is switched off at the main switch. 3.2.1 Setting the ribbon guides A Operator panel support ➔ Loosen the knurled thumb screws on the guide rings [19A]. ➔ Setting the ribbon guides – Distance between label ribbon and front plate of housing: 31.
3 ALS 380 PRIOR TO OPERATING 3.2 MECHANICAL SETTINGS 3.2.2 Adjusting the braking brushes Mounting locations of the braking brushes: – In front of the operator panel support [20A] – On the vertical guide for the dispensing edge [20B] ➔ Loosen the stud bolt [20C]. ➔ Align the braking brush centrally on the label ribbon. ➔ Tighten stud bolts.
3 ALS 380 PRIOR TO OPERATING 3.2 MECHANICAL SETTINGS 3.2.3 Adjusting the pressure rollers A Mounting locations of the pressure rollers: – On the drive roller unit of the unwind unit – On the drive roller unit of the label feed ➔ Loosen the knurled thumb screws on the setting rings [21A]. ➔ Raise the pressure roller slightly and centrally align it on the label ribbon. ➔ Secure the pressure roller axially with the setting rings. Tighten the knurled thumb screws.
3 ALS 380 PRIOR TO OPERATING 3.2 MECHANICAL SETTINGS 3.2.4 Adjust the pressure roller unit (optional) at the dispensing edge. Depending on the area of application, the labeller can be equipped with an additional pressure roller unit [22A] at the dispensing edge. The most favourable positioning of the pressure roller unit differs depending on the application. For information on adjusting the pressure roller unit, the responsible servicing technician is at your disposal.
3 ALS 380 PRIOR TO OPERATING 3.2 MECHANICAL SETTINGS 3.2.5 Adjust (optional) the position D of the dispensing edge. Adjusting vertically Coarse adjustment: ➔ Open the central lock [23B]. ➔ Hold the dispenser head firmly and open the lower lock [23C]. ➔ Slide the dispenser head to the desired height and tighten the lock [23C]. A B Fine adjustment: ➔ Open the upper lock [23A].
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN 4 O P E RA TI ON 4.1 ACTIVATION AND SHUT-DOWN 4.1.1 Starting the machine Before each use, the control system must be adapted to the inserted label material. During this, the label distance is detected and the photoelectric sensor at the dispenser head is adapted to the transparency of the labels and of the backing material. This process is called material initialisation.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN The machine can also be automatically initialised after switch-on by using the INIT function: ➔ In the standard menu, press the NEXT or PRIOR key until INIT [26] is displayed on the operator panel. ➔ Call the INIT function by pressing the ENTER key. ➔ Press and hold the FEED key. – The message AUTO appears on the operator panel. – The machine slowly starts up and dispenses a label.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN 4.1.2 Labelling Prerequisites – Label material is inserted. – Machine is switched on. – Material is initialised. If "OFF" appears on the operator panel: ➔ Press the ENTER [28] key until ON [29A] is shown. [28] ENTER key If "ON" appears on the operator panel [29A]: – The unwinding drive runs for a moment and fills the loop space with label ribbon [29B].
4 OPERATION 4.1 ACTIVATION AND SHUT-DOWN ALS 380 Start dispensing labels – The conveyor belt starts up. The first product reaches the product sensor (photoelectric sensor) [30]. – The product sensor sends a start signal. – The start signal from the product sensor triggers the dispensing of a label (label feed) using the set values for dispensing speed, label distance, etc. – The dispensing of labels automatically runs in the same manner for the following products.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN Unwind unit – A loop forms in the loop space as a buffer between the unwind unit and label dispensing [31arrow]. – A photoelectric sensor in the loop space monitors the loop. – If the loop becomes too large, the control system automatically lowers the unwinding speed. The dispensing speed does not change. – The dancer arm [31A] swings approximately into the centre position.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN 4.1.4 Tandem operation A B [33] Two labellers in tandem arrangement A The active labeller, label roll comes to its end B Labeller in standby with full label roll, “LOCK” appears on the operator panel Principle of operation During automatic switch-over from one machine to the other, the distance between the two machines and their arrangement are taken into consideration. As a rule, unlabelled products can be prevented.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN Prerequisites A – Both machines are configured and tested for tandem operation and automatic dispensing speed adjustment. – Label material is inserted, machines are switched on, material is initialised. – "OFF" appears on the operator panels of both machines. On the machine that is to begin labelling first: ➔ Press the ENTER key [34B]. – The operator panel of this machine indicates ON [34A]. This machine is activated.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN Reloading label material WARNING! Risk of injury from the running conveyor line at the workplace! Risk of pinching at the dispensing edge! ➔ Before reloading label material, ensure that the machine in question does not start up unintentionally. The operator panel must indicate the W__5 warning message. ➔ Absolutely avoid coming into contact with the conveyor line and the moving products.
4 ALS 380 OPERATION 4.1 ACTIVATION AND SHUT-DOWN Switching off Switch over the active machine On the operator panel of the active machine: ➔ Press the FEED [37] key. – The indication on the operator panel changes from ON to BUSY, until the machine stops. – The machine switches over to standby. The operator panel indicates LOCK. – The other machine is activated. [37] FEED key Stopping operation On the operator panel of the active machine: ➔ Press the ENTER key.
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING 4.2 SETTING AND MONITORING 4.2.
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING 4.2.2 Label stop position (STOD) After the label is output, the feed continues to operate, until the next label is present at the dispensing edge. To ensure that the labels separate completely from the dispensing edge, it is advisable to allow the feed to run until the next label projects slightly over the dispensing edge. The label stop position is the distance between the leading edge of the next label and the dispensing edge [40A].
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING 4.2.3 Dispensing speed (VELO) As a rule, the labelling speed must correspond to the product speed. Depending on the operating conditions, the labelling speed can also be set somewhat higher in unique cases. Prerequisites: – The label stop position (STOD) is correctly set. A ➔ In the standard menu, press the NEXT [43A] or PRIOR [43B] key until VELO [44] is displayed on the operator panel. ➔ Call up the VELO function by pressing the ENTER [43C] key.
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING 4.2.4 Label position on the product (POS) – Distance between leading edge of the product and leading edge of the label [45A] Prerequisites: – The label stop position (STOD) is correctly set. – The dispensing speed (VELO) is correctly set. A ➔ In the standard menu, press the NEXT [46A] or PRIOR [46B] key until POS [47] is displayed on the operator panel. ➔ Call up the POS function by pressing the ENTER [46C] key.
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING 4.2.5 Automatic material initialisation (INIT) Also refer to chapter Activation and shut-down. ➔ In the standard menu, press the NEXT or PRIOR key until INIT [48] is displayed on the operator panel. ➔ Call the INIT function by pressing the ENTER key. ➔ Press and hold the FEED key. – The message AUTO appears on the operator panel. – The machine slowly starts up and dispenses a label.
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING 4.2.6 If errors occur Warning messages If the machine control system detects a malfunction, but the labelling operation does not have to be interrupted: – A warning message appears on the LED-indicator of the operator panel. – A warning message is displayed in the format W_nn: W stands for warning, nn is a two-digit numerical code. – An electronic signal is issued at the same time. The signal can be further processed by an external control system.
4 ALS 380 OPERATION 4.2 SETTING AND MONITORING Error messages If the machine control system detects a serious malfunction: – The labelling operation is automatically halted. – An error message appears on the LED-indicator of the operator panel. – A warning message is displayed in the format E_nn: E stands for error, nn is a two-digit numerical code. – An electronic signal is issued at the same time. The signal can be further processed by an external control system.
4 ALS 380 OPERATION 4.3 PRODUCT DATABANKS 4.3 PRODUCT DATABANKS 4.3.1 Functions 4.3.
4 ALS 380 OPERATION 4.3 PRODUCT DATABANKS Activating product databanks at switch-on – The menu Product databanks is only available if at least one product databank is created. ➔ While switching on the machine, press and hold the PRIOR key. – The product databank menu is activated. – The indicator with the last activated product databank [52] blinks. ➔ Repeatedly press the NEXT or PRIOR key until the desired product databank is shown on the display.
4 ALS 380 OPERATION 4.3 PRODUCT DATABANKS 4.3.3 Create/save product databank Prerequisites Saving the product databank CAUTION! Erroneous settings can lead to production setbacks, damage to the machine and system! – Only appropriately qualified and authorised personnel may create product databanks. In the extended menu: ➔ Call up the SAVE function. ➔ Select the desired product databank using the NEXT or PRIOR key. – 11 product databanks are available.
4 ALS 380 OPERATION 4.3 PRODUCT DATABANKS 4.3.4 Deleting a product databank In the extended menu: ➔ Call up the DEL function. ➔ Select the desired product databank using the NEXT or PRIOR key. – Only product databanks that contain data are shown. – The indicator with the last activated product databank blinks. This product databank cannot be deleted. ➔ Delete the selected product databank by pressing the ENTER key. ➔ Exit the extended menu using QUIT.
4 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4 ALS 380 SETTINGS IN THE EXTENDED MENU 4.4.
4 OPERATION 4.
4 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.2 Activating an extended menu Please observe: CAUTION! Erroneous settings can lead to production setbacks, damage to the machine and system, and can even cause work-related accidents! – Only specially trained and instructed personnel may alter the settings in the extended menu. Calling up menu – To access the extended menu, you must enter a password. ➔ Simultaneously press the NEXT and PRIOR keys. – CODE appears on the LED display.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.3 Position of second label (POS2) If the products are to be given two labels: – Distance between the leading edges of the first and second label [58A]. A In the extended menu: ➔ Call up the POS2 function. ➔ Set the desired distance. – Settings are possible in 0.1 mm steps: minimum label length, maximum 999.9 mm – POS2 is not active if the value is set to 0. ➔ Confirm the setting using the ENTER key and exit the POS2 function.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.5 Speed ratio (VERT) – Relationship between the dispensing speed and the conveyor belt speed Example [60]: Circumferential labelling of a round product. The product simultaneously makes a linear movement and a rotational movement. In the extended menu: ➔ Call up the VERT function. – The preset is 100 (corresponds to a ratio of 1:1) ➔ Set the desired value. – Possible settings: 80 to 1000 (corresponds to 0.
4 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU ALS 380 4.4.6 Adjust the label stop sensor (CONT) Technology Automatically adjusting the photoelectric sensor Automatic and manual adjustment ➔ Press and hold the FEED key and switch on the machine at the main switch. – The message AUTO appears on the operator panel. The sensitivity of the label stop sensor must be adjusted to match the transparency of the labels and the backing material.
4 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU ALS 380 Manually adjusting the sensor. In the extended menu: ➔ Call up the CONT function. ➔ Insert the backing material without a label under the photoelectric sensor. ➔ Press the PRIOR key until the yellow LED on the photoelectric sensor [61A] illuminates. ➔ Press the NEXT key in stages until the yellow LED extinguishes again. ➔ Make note of the value displayed when the LED extinguishes: Value of the backing material.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.7 Label distance (LPIT) The label distance is defined as [62]: Label distance = label length + gap The shape of the labels or reflective surfaces can cause a false signal to be sent from the label stop sensor. In such a case, the label distance must be manually set. B In the extended menu: ➔ Call up the LPIT function. ➔ Set the desired distance. – Settings are possible in 0.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.8 Distance from the label stop sensor to the dispensing edge (E–SS) – Correct specification of the distance between the label stop sensor and the dispensing edge is a prerequisite for setting the label stop position (STOD). A Set distance ➔ Adjust the distance between the label stop sensor and dispensing edge. Round the measured value up to a whole number value in mm. In the extended menu: ➔ Call up the E–SS function.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU Check setting ➔ Call up the STOD function. ➔ Set the value for STOD to "0". ➔ Confirm the value using the ENTER key and exit the function. ➔ Press the FEED key. – A label is dispensed. – The leading edge of the next label should rest exactly on the dispensing edge [64]. ➔ Remove a single label from in front of the sensor [65]. ➔ Press the FEED key. – A label is dispensed [66A].
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.9 Product length (PRDL) A start signal can be prematurely triggered by the shape of the product or reflective surfaces. In such a case, the product length must be manually set. Example [67]: If the product [D] reaches the product sensor [C], a start signal is sent and the machine dispenses a label. The recesses in the product trigger additional start signals; without the PRDL function, the product would be labelled several times.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.10 Polarity of the product sensor (P_S_) The product sensor can optionally send the start signal, if – the leading edge of the product passes the sensor [68A]. – the trailing edge of the product passes the sensor [68B]. In the extended menu: ➔ Call up the P_S_ function. ➔ Set the desired polarity.
4 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.12 Number of unlabelled products (MLAB) If products do not get labelled, the operator receives the warning message W_0 at the operator panel. If too many products in a row do not get labelled, the machine stops. The error message E_11 appears at the operator panel. Using the MLAB function, you can determine how many products in a row are allowed to be unlabelled before the machine stops. Example [70]: MLAB is set to value 2.
4 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.14 Advance print start ALS 380 (PDT) When using a printer (optional): The printing process can be started even in the final phase of the label feed. In so doing, the printer stamp is already moving toward the label ribbon, even before the label has come to a standstill - this shortens the printing process. Using the PDT function, you can determine when (after how many motor strokes before label stop) the printing process will be started.
4 ALS 380 OPERATION 4.4 SETTINGS IN THE EXTENDED MENU 4.4.16 Tandem operation (TMOD) 4.4.22 Delete a product data bank load Activate and deactivate tandem operation – Refer to chapter Tandem operation in the service guide. 4.4.17 Applicator type (LOAD) Selecting and loading a product data bank. – Refer to chapter Product databanks, page 48. (APPL) 4.4.23 Create/save product data bank When using an applicator (optional): Set the applicator type used or switch off the applicator.
4 OPERATION 4.5 AUTOMATIC DISPENSING SPEED (APSF) 4.5 ALS 380 AUTOMATIC DISPENSING SPEED (APSF) A [72] A Speed sensor on the conveyor line Conveyor belt and label dispenser are operating in perfect synchronisation. As a prerequisite for this, the speed sensor must be correctly adjusted. Depending on the operating conditions, the relationship between the dispensing speed and the conveyor belt speed must be finely adjusted (the EGRA function).
4 OPERATION 4.5 AUTOMATIC DISPENSING SPEED (APSF) 4.5.1 Electronic transmission ratio of the RPM transmitter (EGRA) – Required compensation factor for the RPM transmitter – For ALS 380 HS, refer to the Service Guide Setting the compensation factor ➔ Calculate the setting value for EGRA: A= resolution of the RPM transmitter used in mm/pulse – Possible settings: 100 ... 650 (factory setting: 600), corresponds to resolutions from 0.10 ... 0.154 mm/ pulse ➔ Call up the EGRA function in the extended menu.
4 ALS 380 OPERATION 4.6 APPLICATOR (OPTIONAL) 4.6 APPLICATOR (OPTIONAL) 4.6.1 Principle of operation If direct labelling from the dispensing edge is not possible, the labeller can be equipped with an applicator. In applicator mode, the applicator takes the label from the dispensing edge and carries it to the product. The labeller can be equipped with various applicators, depending on the need.
4 ALS 380 OPERATION 4.6 APPLICATOR (OPTIONAL) 4.6.2 Functions in the extended menu Please observe the following CAUTION! Erroneous settings can lead to production setbacks, damage to the machine and system, and can even cause work-related accidents! – Only specially trained and instructed personnel may alter the settings in the extended menu. Calling up the extended menu ➔ – ➔ – Simultaneously press the NEXT and PRIOR keys. CODE appears on the LED display. Enter the password [73].
4 ALS 380 OPERATION 4.6 APPLICATOR (OPTIONAL) EP cylinder dwell time (APT1) – Dwell time for the EP cylinder In the extended menu: ➔ Call up the APT1 function. ➔ Set the desired value. – Settings are possible in 1 ms steps: 1 ... 7500 ms ➔ Confirm the setting using the ENTER key and exit the function. Blowing time (APT2) When using a blowing applicator: – Dwell time for blowing the label on the product In the extended menu: ➔ Call up the APT2 function. ➔ Set the desired value.
4 ALS 380 OPERATION 4.6 APPLICATOR (OPTIONAL) Fine tuning of the dwell time (APT4) When using an applicator in combination with the automatic speed adjustment (APSF): – Optimise the accuracy of the label position on the product by fine tuning the dwell time for the applicator. Standard values: – Blowing applicators: approx.
5 ALS 380 AFTER OPERATION 5.1 CARE AND CLEANING 5 A FT ER O P ER A TIO N 5.1 CARE AND CLEANING 5.1.1 Cleaning agents 5.1.2 Regular maintenance Cleaning agents for rubber rollers: – Roller cleaner, ordering code 98925 If other cleaning agents are used, there is some risk of dissolving the rubber. The ALS380 labeller is designed to be maintenance-free. Nevertheless, to ensure long-lasting and reliable operating results, regular maintenance is required.
5 ALS 380 AFTER OPERATION 5.1 CARE AND CLEANING Remove paper waste ➔ Wipe off all paper waste (dust) from all rollers and edges. ➔ Clean the optics of the photoelectric sensors with a soft brush or a soft tissue. Braking brushes ➔ Loosen the stud bolts [75A] and remove the braking brushes. ➔ Remove adhesive residues ➔ Turn the braking brushes and reinstall them so that the side opposite the deformed bristles bears the load.
5 ALS 380 AFTER OPERATION 5.1 CARE AND CLEANING Capacitive sensor at the dispenser head Only if the labeller is equipped with a capacitive sensor [76A] instead of the proper photoelectric sensor: ➔ Remove the knurled thumb screw [76B]. ➔ Remove 2 screws on the underside [77A]. ➔ Remove the upper part of the housing [78A]. ➔ Clean the sensor surfaces [78 arrows] with soft, lint-free rags. A ➔ Reassemble the sensor. ➔ Test the sensor adjustment.
6 ALS 380 OPERATIONAL MALFUNCTIONS 6.1 WARNING MESSAGES 6 O P E RA TI ON A L M AL FU NC TI ON S 6.1 WARNING MESSAGES 6.1.1 Please observe: 6.1.2 If a problem occurs CAUTION! Improper handling of the machine, especially changes to the settings, can lead to serious damage to the machine and system and can cause work-related accidents! – Only the responsible servicing technicians or customer service personnel are authorized to make changes to the settings in the configuration menu.
6 ALS 380 OPERATIONAL MALFUNCTIONS 6.1 WARNING MESSAGES Message Description Possible causes and remedies W__2 Memory errors Factory settings are activated, see appendix. CPU battery is discharged after a long shut-down period of the machine: ➔ Leave the machine switched on for some time to recharge the battery If the accumulatorerror occurs frequently: ➔ Have the CPU battery replaced by the responsible servicing technician. Settings no longer available after software update.
6 ALS 380 OPERATIONAL MALFUNCTIONS 6.2 ERROR MESSAGES 6.2 ERROR MESSAGES 6.2.1 If a malfunction occurs If the control system detects a serious error: – The labelling operation is stopped. – An error code is displayed on the operator panel. If the cause of the error has been eliminated: ➔ Acknowledge the error message by pressing the ENTER key. 6.2.2 Error codes Message Description Possible causes and remedies E__1 The loop space is not filled. Label roll empty: ➔ Replace label roll.
6 ALS 380 OPERATIONAL MALFUNCTIONS 6.2 ERROR MESSAGES Message Description Possible causes and remedies E__2 Label stop sensor does not detect the labels. Ribbon of labels does not run through the slot in the photoelectric sensor: ➔ Check the ribbon guide at the label stop sensor. Label roll empty or more than 3 labels missing: ➔ Replace label roll as required. Pressure roller not closed: ➔ Swing back the pressure roller dispenser head and return it to its position pressing against the roller.
6 ALS 380 OPERATIONAL MALFUNCTIONS 6.2 ERROR MESSAGES Message Description Possible causes and remedies E__7 Photoelectric sensor in the loop space does not detect the loop formation; label stop sensor does not detect the labels and problem with the rewind unit. Refer to E__1, E__2, and E__4.
6 ALS 380 OPERATIONAL MALFUNCTIONS 6.2 ERROR MESSAGES Message Description E_15 Short circuit or Overload of outputs from CN10 ER-U Software error ER-I Software error ER-D Software error ER-T Software error ER-A Software error Possible causes and remedies A check of the connections and output signals by servicing technicians is required; refer to the Service Guide. ➔ Press the ENTER key. ➔ Make note of all the information that is displayed on the control panel.
7 ALS 380 APPENDIX 7.1 FACTORY SETTINGS 7 7.1 A P PE ND IX FACTORY SETTINGS In the case of a memory error: – The message W__2 or E_12 appears on the operator panel. – All databanks are deleted. – The settings of the machine are reset to factory settings [79]. Function Value Explanation VELO 0500 Labelling speed: 50.0 m/min STOD 0000 Distance between dispensing edge and label's leading edge: 0.0 mm POS 0500 Distance between leading edge of product and label: 50.
7 ALS 380 APPENDIX 7.
7 ALS 380 APPENDIX 7.2 PRODUCT DATA BANKS 7.
7 ALS 380 APPENDIX 7.
7 APPENDIX 7.3 EC DECLARATION OF CONFORMITY 7.3 ALS 380 EC DECLARATION OF CONFORMITY We, the: Avery Dennison Deutschland GmbH Ohmstraße 3 D–85386 Eching declare that we have designed and constructed the following designated machine in such a way that it complies with the basic safety and health requirements of the EC Directive.
Avery Dennison Deutschland GmbH Postfach 1163 85385 Eching Germany Telephone: +49-8165-925-0 http://www.machines.averydennison.
