Release 2/08 Artikelnummer: 0089999-08
Operators Manual ALS 321/421 Contents 1. Important Notes........................................................................................................ 3 1.1 Overview....................................................................................................................................... 3 1.1.1 Manufacturer...................................................................................................................... 3 1.1.2 Copyright............................................
Operators Manual ALS 321/421 4.2.1 Product sensor .................................................................................................................24 4.2.2 OD Control sensor ...........................................................................................................25 4.2.3 Control signals .................................................................................................................26 4.3 EMI..................................................................
Operators Manual ALS 321/421 1. Important Notes 1.1 Overview The ALS 321/421 is a fully automatic labeller. Operation is very easy and can be learned with a minimum of training. The machine is controlled by a microprocessor and because of its programmable possibilities it can be used in many applications. Except for cleaning the rolls and light sensor there is no periodical maintenance necessary. This manual should help you to operate the ALS 321/421.
Operators Manual ALS 321/421 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. 1.2.2 Warning Notes in the Text In this description, two types of notes can be found: Warning note – indicates a possible risque of injury for the user.
Operators Manual ALS 321/421 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 321/421 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 321/421 1.2.
Operators Manual ALS 321/421 1.2.
Operators Manual ALS 321/421 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 labeller is available in a right-hand or a left-hand version. The expression right or left is related to the direction of product transport. The material is unwound from the label roll (3).
Operators Manual ALS 321/421 Figure 1 Machine layout Apart from the drive roller (1), and the material brush (6) the labeller has no mechanical wearing parts. The operator panel (19) is described in the next section of this chapter.
Operators Manual ALS 321/421 2.2 Operator panel The operator panel of the 321/421 is shown in Figure 2, it has 4 digit LED and 6 membrane keys. Figure 2 Operator panel The six membrane keys have the following functions: FEED: By pressing this key one label will be dispensed. An error or warning indication may be cleared with this key. Additionally, each time the FEED key is pressed the machine measures the distance to the next leading label edge and stores this measurement as the label pitch.
Operators Manual ALS 321/421 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.
Operators Manual ALS 321/421 3. Labelling 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. 3.1 Threading the Material Before threading the new material, any old rewound backing material should be removed. Pull the cone at roller and take the waste paper from the roll. Open the pressure roller and mount the new label roll.
Operators Manual ALS 321/421 3.1.1 Removing label material Before you mount a new roll of labels, it is necessary to remove the accumulated roll of backing material. Turn the lever the expanding pads retract. The roll of backing material can easily be pulled off the rewind mandrel. Figure 5 Removing label material To ensure a reliable function of the unwind, it is important to exchange the collected backing material each time you mount a new label roll. 3.1.
Operators Manual ALS 321/421 Figure 6 Unwind Unit at the ALS 321 Euro Unwind Unit ALS 321/421 By means of the knurled screw the collapsible key can be moved further in or out for clamping and releasing the label roll. Figure 7 Unwind Unit at the ALS 321/421 The material brush has to be positioned in a way, that the material is kept tight. From time to time, it is recommended to reverse the mounting of the brush while you are loading a new label roll. Mount the label web through the label sensor.
Operators Manual ALS 321/421 Figure 8 Rewind 3.1.3 Adjusting the pressure roller The pressure roller should always be positioned over the middle of the backing material. This ensures accurate label placement. Turn the pressure roller away from the drive roller. Loosen both knurled screws. Move the entire unit to its correct position. Fasten the screws securely again.
Operators Manual ALS 321/421 3.1.4 Lead screw adjustment For adjustments of the dispensing edge towards or away from the conveyor, the lead screw integrated in the labelling head should be used. Positions can be read from the scale on the dispensing edge bars. Adjustment of the dispensing edge Loosen handle 1 and 2 and turn lead screw Z. Once the adjustment is completed pull the handles tight again.
Operators Manual ALS 321/421 Adjust pressure roller Depending on the application the foam roller has to be adjusted. Loose the both screws and tighten the screws again after the adjustment was done. Figure 11 Adjust pressure roller 3.2 Starting labelling For the labelling operation, four adjustments are necessary: 1. The contrast value for detecting the gap between the labels has to be adjusted. By pressing the contrast key the value changes between 0 and 255.
Operators Manual ALS 321/421 The value will be increased. The label is positioned nearer the leading edge of the product. The value will be lower. The label is position nearer the end of the product. 3.3 Using the FEED key to measure the label pitch Each time the FEED key is used to feed the label web the machine measures the distance to the next leading label edge and stores this measurement internally as the label pitch.
Operators Manual ALS 321/421 3.6 Maintenance The machine can be easily maintained and has only a few wear parts. If you change any material, note if any glue or waste labels are stuck on the rolls or dispensing edge. In this case, you have to clean the respective parts. The machine has to be cleaned at least once a week. Glue and waste labels have to be removed from the rolls, the dispensing edge and the material brush. All rollers have to be cleaned from any grease.
Operators Manual ALS 321/421 4. Connections This machine has a number of inputs to connect sensor’s and a control. Outputs are available for applicators, a printer and other purposes. 4.1 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 321/421 4.1.5 Labelling signals For direct dispensing the airstream signal can be used to control a pneumatic driven dispensing edge. Ready 4 Product start 3 1 Label start Suppression Product start Suppression PRDL POS POS Dispense POS 2 Motor run signal APOS ASTP 1 Productstart disabled. PRDL activ 2 Missing Label: New start of dispense during dispenser activ 3 Inhibit activ 4 Machine not ready.
Operators Manual ALS 321/421 4.2 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. The inputs are galvanically separated through photo couplers to connect to PNP or NPN outputs. The wiring and the connection of the signal plug is shown otherwise. The input voltage across the inputs must be in the range of 15 V to 30 V to switch active.
Operators Manual ALS 321/421 4.2.1 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 321/421 4.2.2 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 321/421 4.2.3 Control signals An optional connector could be installed for integration of the machine in the line control.
Operators Manual ALS 321/421 Figure 19 Internal I/O connector Release 2/08 Page 27 Connections
Operators Manual ALS 321/421 Figure 20 Wiring diagram Release 2/08 Page 28 Connections
Operators Manual ALS 321/421 Figure 21 Layout dispenser electronic board Release 2/08 Page 29 Connections
Operators Manual ALS 321/421 48VAC 48VAC Phase1A Phase1B + Direction - Direction - Clock + NC - NC Ready Collector Ready Emitter 800 Resolution 400 Ready LED LED Voltage Overtemperature 100% on Short circuit 25% on / 75% off Both 75% on / 25% off Figure 22 Layout stepper motor driver The jumper position has to be 800 steps.
Operators Manual ALS 321/421 4.3 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 321/421 5. Errors and warnings The software continuously checks during the labelling, whether normal operation is possible. If labelling is not possible, the display shows a message e.g. E_XX. If labelling can be continued, although a problem has been recognised, the display shows a warning e.g. W_XX. By pressing the key FEED the message will be erased. Error and warning signals are available at the outputs and may be used for external purposes.
Operators Manual ALS 321/421 Message Meaning How to solve ___1 Illegal interrupt (processing error) ___2 Illegal bank interrupt (processing error) INTO Illegal interrupt INTP0 (processing error) Hardware failure external noise. EPROM damaged. Turn off power and on again. Change EPROM or main board Hardware failure external noise. EPROM damaged. Turn off power and on again. Change EPROM or main board Hardware failure external noise. EPROM damaged. Turn off power and on again.
Operators Manual ALS 321/421 6. Technical specification The following data are maximum values. Depending on label material, operation environment and labelling condition the real value could be lower. 6.1 Technical Information Description Label width: incl. Backing paper ALS 321 ALS 421 10 mm ... 155 mm 10 mm ... 230 mm Label length 10 - 220 mm Diameter label roll max.
Operators Manual ALS 321/421 6.2 Application specification The labeller is designed and built for automatic applies of self-adhesive labels. 6.3 Performance charts The following charts show the maximal theoretically labels per minute rate. Tolerances in product speed, label and product dimensions reduce the label rate. The charts 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 V3.
Operators Manual ALS 321/421 mm 9 8 7 6 5 4 3 2 1 0 0 5 10 15 20 25 30 m/min 10 15 20 25 30 m/min Figure 25 Acceleration mm 10 9 8 7 6 5 4 3 2 1 0 0 5 Figure 26 Stop delay Release 2/08 Page 36 Technical specification
