OPERATING MANUAL Label print dispenser A103131 ALX 734/735 736 Edition 4 - 3/2012 - Translation of original version
ALX 73x GB CONTENTS Please note Entire unit ............................................................12 Dimensions .....................................................12 Connection, unit data ......................................13 Label material .................................................13 Ambient conditions ..........................................14 Certificates ......................................................14 Print module ........................................................
ALX 73x CONTENTS Setting the printhead pressure ........................78 Setting the return force of the unwinder dancer lever ....................................................79 Setting the return force of the linear dancer lever ....................................................80 Switching the unit on and off ...............................81 Switching the machine on/off ..........................81 Setting and monitoring the dispenser ..................82 Settings in parameter menu ..............
ALX 73x GB PLEASE NOTE General notes Validity of this manual and required compliance Contents The complete operating manual for the ALX 734, ALX 735 and ALX 736 print dispensers consists of the following parts: • Operating manual (for operating personnel) • Service manual (for service personnel) • Spare parts catalogue (for service personnel) This operating manual refers exclusively to the machine types listed above. It is used for proper operation and adjustment of the machine.
ALX 73x PLEASE NOTE Manufacturer Avery Dennison Deutschland GmbH Ohmstrasse 3 D-85386 Eching, Germany Tel.: +49-8165-925-0 Fax: +49-8165-925-231 www.monarch.averydennison.
ALX 73x GB PLEASE NOTE How information is represented Explanation of symbols To enhance readability and make information easier to find, different types of information are identified: Instruction with no order of tasks assigned 1. Numbered instructions introduced by preceding text 2. The specified order must be followed! Special note for action that must be performed. Explanation of an error cause in the reference of error messages.
ALX 73x PLEASE NOTE For your safety Intended use Label print dispensers of series ALX 73x are designed for printing, dispensing and applying self-adhesive labels using the direct thermal or thermal transfer procedure. The individual versions (ALX 734, ALX 735, ALX 736) differ in the maximum print width. Different combinations of thermal transfer ribbons and label materials are used and must be available in the form of rolls. The label material that is used must be punched, i.e.
ALX 73x GB PLEASE NOTE • The system integrator must be acquainted with the functionality of the of the system into which the label dispenser is being integrated.
ALX 73x PLEASE NOTE Operating safety of the machine Intended use The machine must only be used in accordance with the specifications in section Intended use on page 6. Warning of injuries due to electrical shock WARNING! This unit operates at mains voltage! Contacting electrically live components can cause lethal electrical shocks and burns. Only operate the machine when the enclosure is properly installed.
ALX 73x GB PLEASE NOTE Warning of injury hazards from mechanical components WARNING! Danger of injury due to moving and rapidly rotating parts! Maintain a safety clearance from the machine when it is in operation. Never reach into a machine that is running. Switch off the machine before making any mechanical adjustments. Keep clear of the area around moving parts even when the machine is stopped if there is any possibility of the machine starting up.
ALX 73x PLEASE NOTE Every time before starting production Due diligence of the operator and service personnel Ensure that the following requirements are met in accordance with details specified in the service manual: • • • • The machine must be set up and configured to meet applicable requirements. All necessary safety equipment must be installed. The machine must have successfully completed at least one test run. The machine must be connected to the energy supply.
ALX 73x GB PLEASE NOTE Warning notes on the machine CAUTION! Warning notes on the machine provide important information for the operating personnel. Do not remove warning notes. Replace missing or illegible warning notes. [1] Warning notes on the ALX 73x Warning note [tab. 2] Meaning Article no. The ´Pinch point´ warning note warns you of the danger posed by the machine´s rotating parts; they can trap items and draw them in.
ALX 73x TECHNICAL DATA Entire unit Dimensions Dimensions The amount of space required by the machine depends on which configuration is used (see installation instructions in the Service manual). • ALX 734/5: 1054 x 905 x 470 mm (H x W x D) 1 • ALX 736: 1054 x 905 x 513 mm 470 (ALX 734/5) 513 (ALX 736) 740 1054 420 905 860 [2] Weight Dimensions of a ALX 73x with top-mounted 400 mm unwinder without dispensing edge. The weight of the machine depends on the configuration that is used.
ALX 73x GB TECHNICAL DATA Connection, unit data Protection rating "I" Mains voltage 100-240 V (AC) Mains frequency 60/50 Hz Power consumption Max. 750 W Power input 7.5 -3.0 A Label material Material types Self-adhesive, punched labels on carrier material. Thermal direct material, thermal transfer material, plastic ribbon: PE, PP, PVC, PA in rolls.
ALX 73x TECHNICAL DATA Ambient conditions Operating temperature 5 to 40°C Storage temperature -4 to 60°C Air humidity 45 to 75% (non-condensing) Protection class IP 21 Noise emissions < 70dB(A) Certificates CE, TÜV-Mark, CTÜVUS -Mark, FCC, GOST 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.
ALX 73x GB TECHNICAL DATA Print module Performance data Printing technology Thermal direct or thermal transfer printing Printhead type "Corner Edge" type Printhead variables Printer Resolution (dots/mm) Resolution (dpi) Print speed (mm/s) Print speed (inch/s) Max. print width (mm) ALX 734 12.0 300 50-400 2 -16 104 ALX 735 12.0 300 50-400 2 -16 127 ALX 736 12.0 300 50-300 2 -12 160 [tab. 4] Label sensor Printhead variables.
ALX 73x TECHNICAL DATA Character sets Code pages • • • • 17 character sets with fixed size (fixedfonts) including OCR-A and OCR-B • • • • • • DOS 437 3 Scalable character set (speedo fonts) TrueType character sets are supported (in Unicode as well) TrueType, speedo and fixed size fonts can be optionally stored on a memory card DOS 850 ANSI 1250 ANSI 1252 UTF 8 Legacy code page (7 bits) Character modification • Scaling in x/y direction up to a factor 16 • Rotation by 0, 90, 180, 270 degrees Impress
ALX 73x GB TECHNICAL DATA Barcodes Codabar Code 128 A, B, C Code 128 Code 128 UPS Code 128 Pharmacy ITF Code 2/5 matrix MSI Code 2/5 Interleaved EAN 8 Code 2/5 5 lines EAN 13 Appendix 2 Code 2/5 Interleaved Ratio 1:3 EAN 13 Appendix 5 Code 2/5 Matrix Ratio 1:2.5 EAN 128 Code 2/5 Matrix Ratio 1:3 Postal code (guide and ID code) Code 39 UPC A Code 39 Extended UPC E Code 39 Ratio 2.
ALX 73x TECHNICAL DATA Thermal transfer ribbon Winding direction Roll Coloured side wound inward or outward Variable Dimension Outer Ø max. 110 mm 1 25,4 mm (1") Core inside Ø 40,2 mm (1.6") 2 Width 3 [tab. 5] 1) 2) 3) 20 -140 mm Dimensions of usable ribbon rolls. Corresponds to 1000 m standard ribbon type Avery 2240 with a ribbon core of 40.2 mm. With ribbon core adapter (accessory) As a general rule, the thermal transfer ribbon must overlap the label being printed on both sides by 2 mm.
ALX 73x GB TECHNICAL DATA Electronic equipment Feature Details CPU 32 Bit MIPS RAM 64 MB ROM 4 MB Memory cards SD (1 slot) CF I/II (1 slot) Real-time clock Fitted Control panel 5 keys; LCD graphical display with 128x32 pixels; typically two lines are displayed with 16 characters each [tab. 7] Electronic equipment for print module ALX 73x.
ALX 73x TECHNICAL DATA Dispensing module Variables Dispensing speed Up to 50 m/min Label stop accuracy on At a constant dispensing speed: ± 0.5 mm the dispensing plate At a variable dispensing speed (range of 5-50 m/min): ±1.0 mm Speed control Fixed setting or automatic speed adaptation via encoder.
ALX 73x GB TECHNICAL DATA External sensors Interface Details Label sensor Wenglor OPT242-P800 optical, NPN, 24 V, controllable sensitivity Product sensor PNP/NPN, 24 V Loop sensor APSF sensor (rotary encoder) One/two-phase , PNP/P-P, 24 V, max. 20 kHz Material reserve sensor PNP, 24 V [tab. 10] Interfaces for external sensors on the ALX 73x dispensing module (plugs are 4-pin M12).
ALX 73x PRODUCT DESCRIPTION Overview Designs of the ALX 73x ALX 734/735 The ALX 73x is available in versions ALX 734, ALX 735 and ALX 736. These two versions differ in the width of the printhead: • ALX 734: 4" print width (106 mm) • ALX 735: 5" print width (127 mm) • ALX 736: 6“ print width (160 mm) ALX 73x RH/LH Each machine of series ALX 73x is available as a right-hand (RH) or left-hand (LH) version [5]: • ALX 73x RH: The label exits the machine on the right 1.
ALX 73x GB PRODUCT DESCRIPTION Configurations of the ALX 73x The ALX 73x can be adjusted in many ways to meet customer requirements: Feature Adjustment Direction in which products move Selection of design: LH / RH Assembly position of the machine Horizontal / vertical (for labelling from above or from the side) Machine fastening Below / in the rear Number of unwinders 1/2 Fastening of unwinders Above (to the right / left) On the side (right / left) [tab. 12] Options for configuring the ALX 73x.
ALX 73x PRODUCT DESCRIPTION A D B C E F [6] Left: Functional elements of the ALX 73x. Right: Flow of material. A Unwinder B Dispenser (LMA) C Printer (PMA) D Dancer unit (DU) E Dispensing edge holder F Dispensing edge (optional) Sequence of print dispensing: • A print job is transferred to the printer (via database interface or memory card). • The printer starts. When it does the dancer lever of the dancer unit moves up.
ALX 73x GB PRODUCT DESCRIPTION Operating components A B C D E P F O G H I Q J N K M L [7] Operating components of the ALX 73x RH. A Unwinder The unwinding mandrel receives the material roll. B Dancer lever Holds the label material evenly under tension. Brakes the rotation of the material roll if the material tension drops. C Core diameter adapter To adjust the diameter of the dispenser mandrel to the core diameter of the label roll.
ALX 73x PRODUCT DESCRIPTION F Rewinder Winds up the empty carrier material. G Unlocking button Pressing the button reduces the diameter of the rewinding core. This makes it possible to remove wound carrier material easily. H Dispenser control panel (dispensing module "LMA") To enter commands on the dispensing section of the machine and display operating states and error messages. I Pressure mechanism Presses the pressure roller against the drive roller. Prevents the carrier material from slipping.
ALX 73x GB PRODUCT DESCRIPTION B A D C E I E F G H [8] Operating components of the printer in a ALX 73x RH. A Printer control panel (print module „PMA“) To enter commands on the printing section of the machine and display operating states and error messages. B Front cover Held open by gas pressure spring. C Ribbon unwinding mandrel Holds the ribbon roll. D Ribbon winding mandrel Winds up the used ribbon. E Material guides The material end sensor is located inside the material guide.
ALX 73x PRODUCT DESCRIPTION Control panels Control panel language Different languages are available for texts that appear on screen. Instructions for selecting the language: • Dispenser: see Setting parameters on page 42. • Printer: see Setting parameters on page 48. Printer control panel A B C ON ERROR D E APPLY ONLINE FEED [9] PROG Printer control panel. A On/Off switch Switches the printer on and off. To do this, press this button for longer than 2 seconds.
PRODUCT DESCRIPTION ALX 73x GB Dispenser control panel A B C D [10] Dispenser control panel. A Operating LED Lights up green when the dispenser is turned on. B Error LED Lights up red when an error has occurred. C Screen Display of operating states, parameters, setting values and error messages. The displays depend on the operating state of the dispenser. They are described in section Operating modes of the dispenser on page 37.
ALX 73x PRODUCT DESCRIPTION Connections WARNING! Danger of electrocution. Only connect the printer to devices that fulfil the SELV (safety extra-low voltage) circuit requirements in accordance with EN 60950. CAUTION! Danger of damage to the machine due to faulty accessories. Only connect original accessories. H U A V B W C D I J K X E F G Y N L M O Q M P T Z RS [11] Connections on an ALX 73x RH. Left: printer connections, right: dispenser connections.
ALX 73x GB PRODUCT DESCRIPTION H Connection to the mains power supply I Label sensor J Product (start) sensor (available as accessory) K Rotary encoder (available as accessory); used for operation with automatic speed adaptation L Alternative label sensor (see Capacitive label sensor on page 35) M Position sensor of the linear dancer lever N OD 1 sensor for external OD monitoring (see Roll diameter sensor on page 34) O (Dispenser) signal inputs (connection only to ALX 73x in the "complete") desig
ALX 73x PRODUCT DESCRIPTION Options External control panels In addition to the permanently installed control panel, external control panels can also be connected. External control panels are advantageous if the installed control panels are difficult to access due to the installation position of the machine. [12] External dispenser control panel Fixed dispensing edge The dispensing edge is rigidly connected with the holding bars.
ALX 73x GB PRODUCT DESCRIPTION Pneumatic dispensing edge The dispensing edge can be rotated in the dispensing head. Compressed air presses the dispensing edge onto the surface of the product. This makes it possible to compensate for differences in height between products or on the surface of the product. [16] Pneumatic dispensing edge V-shape dispensing edge The length-adjustable V-shape dispensing edge [17] offers an additional opportunity to adapt the machine to the application.
ALX 73x PRODUCT DESCRIPTION Adjustable head joint Using the adjustable head joint [19A], just one person can tilt the label dispenser ±4° for fine dosing. A [19] Adjustable head joint (A) Roll diameter sensor A The roll diameter sensor (OD sensor) [20A] generates a warning if a specific, adjustable Outer Diameter of the roll is exceeded.
ALX 73x GB PRODUCT DESCRIPTION Additional material guiding disc The additional material guiding disc [22A] improves side guiding of the material roll. This option is especially recommended for processing very narrow label material (< 30 mm in width). A [22] Additional material guiding disc (A) Capacitive label sensor Optional sensor, required for processing transparent labels [23A]. The sensor is mounted on the rods of the dispensing edge holder. A [23] Capacitive label sensor (A).
ALX 73x PRODUCT DESCRIPTION Blow-on applicator LA-BO The LA-BO applies labels to products without touching them. It suits especially well for labelling delicate products like fruits or vegetables. [25] Applicator LA-BO. Tamp-on applicator LA-TO The LA-TO presses labels onto products by means of a movable pressure plate, which is driven pneumatically. Pressure plates are available in different sizes. [26] Applicator LA-TO.
ALX 73x GB PRODUCT DESCRIPTION Operating modes of the dispenser Overview Operating modes of the dispenser: • Online mode – dispensing mode – Active operating mode after switching on 1 – Label counter screen or – Display/setting of dispensing speed and start delay • Offline mode Settings in parameter menu [28] Dispenser control panel on the ALX 73x.
ALX 73x PRODUCT DESCRIPTION Online mode ON STATUS Online 292 Labels – + – + A [29] Dispenser control panel in online mode (292 labels dispensed) A Meaning of keys in online mode Activate online mode Normally 1 activated automatically after switching on. Activate from offline mode: Press the key 2x. Screen: ONLINE Label 0 Or: Prof 5 xxxxxxx Label 292 (Product profile "xxxxxxxx" (memory slot 5) is activated).
ALX 73x GB PRODUCT DESCRIPTION Continue label output: 1. (applicator mode) remove label from applicator. 2. Press the Online settings key. A B C ON STATUS Offset 0.0 Speed 12.2 fix – + – + E F G D H [30] Dispenser control panel in the online settings mode.
ALX 73x PRODUCT DESCRIPTION Changing the counter state Set the counter state with MACHINE SETUP > Dispense counter. Count labels backwards To count dispensed labels backwards from a starting value to zero: 1. Set LABEL SETUP > Stop counter mode to "Enabled“. 2. Define the starting value with LABEL SETUP > Label stop quan.. Start dispensing cycle To start dispensing of a single label manually: Press the To start the dispenser in offline mode key.
ALX 73x GB PRODUCT DESCRIPTION Offline mode Activate offline mode Activate from online mode: Press the key 2x. OFFLINE Press the key. LABEL SETUP LABEL SETUP is the first menu in the parameter menu. In offline mode the key assignments as they are represented under the keys apply. Opening the parameter In the parameter menu the user has access to a number of menus in which various menu parameters can be called in a defined order.
ALX 73x PRODUCT DESCRIPTION Setting parameters MACHINE SETUP MACHINE SETUP Dispenser type 5x Language English MACHINE SETUP Language B MASCHINEN SETUP Sprache Language German A [32] Key function when setting the parameter MACHINE SETUP > Language. A Key for "Accept change" B Key for "Reject change" Each menu contains parameters that can be used to make settings on the machine control unit. Fig.
ALX 73x GB PRODUCT DESCRIPTION Printer operating modes Overview Operating modes of the printer: • Online mode – Print jobs are received and processed immediately – Active operating mode after switching on – Print contrast setting • Offline mode – Print jobs are received but are not processed – Access to the parameter menu • Standalone mode – Print mode without data line – Print job on memory card ON ERROR APPLY ONLINE FEED PROG [33] Dispenser control panel on the ALX 73x.
ALX 73x PRODUCT DESCRIPTION Online mode ON ERROR ONLINE A 0: JOBS APPLY ONLINE FEED B PROG [34] Printer control panel of the ALX 73x in online mode. A Interpreter activity B Data transfer Activate online mode Activate from offline mode: Press the Enter key. Screen: ONLINE 0 JOBS (There are no pending print jobs for processing).
ALX 73x GB PRODUCT DESCRIPTION Screen showing the progress of printing Screen during printing: • Number of print jobs interpreted (13) • Number of remaining labels to be printed in the current job (25) ONLINE 13 JOBS Restcount: 25 ONLINE 13 JOBS Restcount: endless If a printer job has been specified as endless, i.e., there is no limit to the number of labels to be printed, the remainder for this job will also be endless.
ALX 73x PRODUCT DESCRIPTION Offline mode Activate offline mode Normally 1 activated automatically after switching on. To activate from online mode (when the print job is stopped): Press the Enter key. OFFLINE 0 JOBS (There are no pending print jobs for processing). OFFLINE xx JOBS Stopped: yy (The operator has switched from stopped online mode to offline mode) Material feed forwards/ Material feed up to the start of the next label: backwards Press the feed key. OFFLINE xx JOBS feeding...
ALX 73x GB PRODUCT DESCRIPTION Opening the parameter In the parameter menu the user has access to a number of menus in which various menu parameters can be called in a defined order. The dispenser can be set so that some menus and/or parameters are not visible. Figure [35] shows the key functions for switching between different menus and for exiting the parameter menu.
ALX 73x PRODUCT DESCRIPTION Setting parameters SYSTEM PARAMETER SYSTEM PARAMETER Speed unit Language English SYSTEM PARAMETER Language B Language German A SYSTEM PARAMETER Sprache [36] Key function when setting the SYSTEM PARAMETER > Language parameter. A Key for "Accept change" B Key for "Reject change" Each menu contains parameters that can be used to make settings on the machine control unit. Fig.
ALX 73x GB PRODUCT DESCRIPTION Standalone mode In standalone mode, print jobs are not transferred via data cable but are instead stored on a memory card. You can access them there from the printer control panel or using a connected keyboard. Activate standalone mode 1. Switch off the machine. 2. Save relevant print jobs in the \Formats directory on the memory card. Files with print jobs must have the ending *.for. 3. Insert the memory card in the printer's card slot. 4. Switch on the machine.
ALX 73x PRODUCT DESCRIPTION Dispenser parameter menu Overview of parameter menu LABEL SETUP MACHINE SETUP (continued) INTERFACE PARA (continued) Load prod.profil Dispenser type Slave IP address >EASYPLUGINTERPR Port address Gap detect. mode Store prod.prof. Tandem Distance Interface Ethernet speed Dispense speed Del. prod.profil Label sens. type Spooler mode MAC Address Slew speed Dispense counter Labelsen. InType Dispenser ID no. SNMP Agent Label pitch Turn-on mode Startsen. In.
ALX 73x GB PRODUCT DESCRIPTION SIGNAL INTERFACE (continued) SERVICE/DIAGNOS. SERVICE DATA (continued) Interface mode >AI BOARD SIGNAL Service >MODULE FW VERS. Manufacturer >PLC SIGNALS Applicator type Serv. data reset System version Work place End dispense mod Apply mode Sensor Test System revision Company name Disp.
ALX 73x PRODUCT DESCRIPTION Information about the parameter description • The setting range or the individual settings of a parameter are shown in square brackets. • For parameters with individual setting values, the preset value is shown in italic type. Tips for data entry in the parameter menu Line overflow If the displayed text is longer than the length of the line in the display: Move text to the left: Press the key. Move text to the right: Press the Entering network addresses key.
ALX 73x GB PRODUCT DESCRIPTION Slew speed Feed speed during initialisation Setting range: [5.0…50.0] m/min; default: 1,0 Label pitch Label pitch = label length+gap Setting range: [5,0…600,0] mm; default: 100,0 mm Lab. stop offset Stop position of the label on the dispensing plate Setting range: [0,0…999,9] mm; default: 20,0 Start offset Distance between product sensor and the tip of the dispensing plate. The setting affects the position of the label on the product.
ALX 73x PRODUCT DESCRIPTION Disabled: Dispensing counter counts forwards, i.e. each label that is dispensed increases the counter state. Label stop quan. After dispensing this number of labels, the dispenser stops This function only appears if LABEL SETUP > Stop count. mode = "Enabled" Setting range: [0…99999]; default: 0 MACHINE SETUP menu Store prod.prof. Save the current settings as a product profile With the exception of functions MACHINE SETUP > Dispense counter and LABEL SETUP > Label stop quan.
ALX 73x GB PRODUCT DESCRIPTION Materialend warn Related to internal OD monitoring. • Settings: [Disabled, „Mat.diam < x mm“] • Setting range for x = [50…500] • Default setting: x= 80 Disabling the function: Set x < 40. Re-enabling the function: Press the key. Defines the diameter threshold for the material roll.
ALX 73x PRODUCT DESCRIPTION Printer parameter menu Overview of parameter menu PRINT INFO PRINT PARAMETERS INTERFACE PARA. SYSTEM PARAMETER (DP INTERFACE) … Print speed … … … Feed speed Light sens. type Material type … Material length Ribbon autoecon. Material width Ribb. eco. limit Print direction … … Print contrast X - Printadjust … Y - Printadjust … [tab. 16] Printer parameter menu part 1 (firmware 6.
ALX 73x GB PRODUCT DESCRIPTION PRINT PARAMETERS menu Print speed Print speed The print speed (material feed) can be adapted to the combination of ribbon and material in use to optimise the contrast intensity and the degree of blackening of the print image. Setting range: [2…16] inch/s; presetting: 8 inch/s Feed speed Feed speed The feed speed can be increased in areas with no print. This reduces the overall print time, especially for long labels with very little printed surface.
ALX 73x PRODUCT DESCRIPTION Settings: ["Foot first", "Head first"] • "Foot first": Alignment of the print image as shown in [37A]. • "Head first": Alignment of the print image as shown in [37B]. Note the following: Define the "true" label length (without label gaps) in parameter PRINT PARAMETERS > Material length. If the label gap is longer than 5 mm parameter SYSTEM PARAMETER > Miss. label tol. must also be set to a value greater than zero.
ALX 73x GB PRODUCT DESCRIPTION • "Thermal/head lift": Thermal direct printing with automatic head lifting over unprinted areas (protects the printhead) • "Thermal printing". Thermal direct printing (ribbon end sensor shut off) • "Enabled": Thermal transfer printing with ribbon saving • "Off": Thermal transfer printing without ribbon saving Ribb. eco.
ALX 73x PRODUCT DESCRIPTION • With adjust para Parameters containing device-specific settings are saved as well. The relevant parameter names are marked in the text file with a *. Application: Service Pre-set filename: SETUPALL.FOR Store diagnosis Saves diagnostic data to memory card. Pre-set filename: Diagnose ALX 735 PMA RH A662105104002453.
PRODUCT DESCRIPTION ALX 73x GB SERVICE FUNCTIONS menu Head dot test Checks the printhead for faulty dots. The check ends with a status report [38] containing a list of faulty dots. This printout is generated even if no faulty dots were found. CAUTION! Danger of damage to the printhead. Do not switch off the printer under any circumstances during the dot check! Failure to observe this instruction may cause dots to be destroyed. The following screen appears during the check: Head dot test Please wait ..
ALX 73x STARTUP AND OPERATION Electrical connections WARNING! This unit operates at mains voltage! Contacting electrically live components can cause lethal electrical shocks and burns. The machine must only be connected to the mains power supply by an authorised specialist. This person must be acquainted with the associated dangers. Only operate the unit at the mains voltage given on the type plate. Make certain the units is switched off before you plug in the mains power connecting line.
ALX 73x GB STARTUP AND OPERATION Connecting sensors B WARNING! This unit operates at mains voltage! Contacting electrically live components can cause lethal electrical shocks and burns. A The machine must only be connected with other machines if they meet the requirements of a SELV circuit (Safety Extra-Low Voltage circuit) in accordance with EN 60950. D G H required sensors are securely connected [41].
ALX 73x STARTUP AND OPERATION Inserting label material WARNING! Danger of injury due to moving and rapidly rotating parts! Before inserting the label roll ensure that the printer and dispenser are both in offline mode. Danger of injury caused by falling label roll. Wear safety shoes. Inserting the label roll 1. If necessary, adjust the diameter of the unwinding mandrel to the core diameter of the material roll; see section Adjusting the core diameter of the unwinder on page 75. 2.
STARTUP AND OPERATION ALX 73x GB Threading in the label web Threading diagrams The following illustrations show the flow of material 1 through the ALX 73x in different installation positions and designs with right-hand and left-hand versions. [45] Flow of material with horizontal installation and one unwinder. [46] Flow of material with horizontal installation and two unwinders. 1) Solid line: flow for material rolls with labels on the outside.
ALX 73x STARTUP AND OPERATION [47] Flow of material with vertical installation and one unwinder. [48] Flow of material with horizontal installation, one unwinder and double roller at the dancer lever.
STARTUP AND OPERATION ALX 73x GB [49] Flow of material with horizontal installation, one unwinder and V-shape dispensing edge.
ALX 73x STARTUP AND OPERATION Threading the label web into the printer 1. Open the printer cover [50]. Hold the cover on the bottom right [50A]. 2. Adjust the material guide to the width of the label web. To do this, release the thumb screw [51A] on the outer material guide [51B], push the material guide up to the edge of the label material and screw in the thumb screw again until it is tight. The label material should move easily between the guides. 3.
ALX 73x GB STARTUP AND OPERATION Thread in the label web on the dispensing edge Fixed [53] and swivelling L-shape dispensing edges: 1. Guide the backing paper around the first deflection roller [53A] and through the slot in the sensor [53B]. 2. Guide the backing paper under the pressure roller [53C] to the dispensing plate [53D]. 3. Guide the backing paper around the dispensing plate to the second deflection roller [53E]. 4.
ALX 73x STARTUP AND OPERATION Thread in the label web on the drive roller 1. Open the pressure roller. To do this turn the lever [56A] clockwise. 2. Position the backing paper around the deflection roller [56B] and drive roller [56C]. 3. Close the pressure roller. To do this turn the lever [56A] anticlockwise until you feel it snap into place. B A C B [56] Open the pressure roller. Thread the label web onto the rewinder 1. Guide the backing paper around the deflection roller and dancer lever [57]. 2.
ALX 73x GB STARTUP AND OPERATION Replacing a label roll Detecting end of roll To keep downtimes during production as short as possible, the roll should be changed as quickly as possible. Threading the label material through the entire machine is relatively time consuming. Threading in can be avoided by connecting the beginning of the new material roll to the end of the old material roll (= splicing). This means that the material end must be detected before it is too late.
ALX 73x STARTUP AND OPERATION Inserting/replacing ribbon WARNING! Rotating parts can entrap objects and body parts and draw them in! Never wear loose long hair, loose jewellery, long sleeves or similar items when working with the machine. Always close the printer cover before printing. The printhead can become hot during operation! Be careful whenever touching the printer. CAUTION! [62] Threading diagram for ribbon.
STARTUP AND OPERATION ALX 73x GB Changing ribbon With roll diameter monitoring We recommend switching on roll diameter monitoring, see section Ribbon reserve on page 89. As soon as the critical diameter is reached, the message appears: FOIL X JOBS Follow these steps: 1. Open the front cover. The printer prints the current label completely and then stops. Print status: 5103 Cover open As soon as the buffer loop is empty, the dispenser also stops. 2. Changing a ribbon roll. 3. Close the front cover.
ALX 73x STARTUP AND OPERATION 5. Press the feed key. The last (incomplete) label to be printed will be printed again. Then printing continues with the current print job. Now the label that was not completely printed must be removed. As soon as the label that was not completely printed is at the front of the buffer loop [65A]: 1. Press the Enter key. The printer prints the current label completely and then stops. As soon as the buffer loop is empty, the dispenser also stops. A 2.
ALX 73x GB STARTUP AND OPERATION Mechanical settings Adjusting the core diameter of the unwinder B Tools: B 3 mm hexagonal (Allen) key wrench The unwinder can be adapted to the internal diameter of the label rolls using core adapters [66A]. Depending on this diameter, various adapters will have to be installed or removed: 38.1 mm (1") core: Unscrew the bolts [66B] (2 for each adapter) and re- A move the adapters. 76.2 mm (3") core: Tighten the adapters as shown in figure [66].
ALX 73x STARTUP AND OPERATION Position the label sensor on the dispensing edge 1. Loosen the thumb screw. 2. Push the sensor into place on the axis so that it can detect the gaps between labels. LED [69A] is lit when the sensor is standing over a label. A B A [69] Label sensor at the fixed L-shape dispensing edge. Position the label sensor in the printer The printer is equipped with a combination transmission/reflex sensor.
ALX 73x GB STARTUP AND OPERATION Setting the ribbon tension For optimum printing results, the ribbon must run without creases. This can be achieved by correctly setting the torque on the rewinding mandrel and the braking torque on the unwinding mandrel. The factory settings cover a wide range of different ribbon widths. It may be necessary to readjust the ribbon tension for very narrow or very wide ribbons.
ALX 73x STARTUP AND OPERATION Setting the printhead pressure CAUTION! Shortened service life of printhead. A Always set the weakest printhead pressure that will produce acceptable printing results. Different material widths and thicknesses affect the contact pressure of the printhead on the print roller.
ALX 73x GB STARTUP AND OPERATION Setting the return force of the unwinder dancer lever The dancer lever on the unwinder is set so that a wide range of label materials can be processed without having to change the setting of the dancer lever return force. A Very narrow label material may tear in some circumstances or may be stretched so much that dispensing accuracy is impaired. If this happens, the dancer lever force must be reduced: Unwinder with diameter of 400 mm 1. Loosen the lock ring [76B].
ALX 73x STARTUP AND OPERATION Setting the return force of the linear dancer lever A The linear dancer lever is set so that a wide range of label materials can be processed without having to change the setting of the dancer lever return force. Adjusting the return force: 1. Pull out the knob [78A]. The knob is under spring tension. Hold onto the knob firmly until it locks into place again. 2. Turn the knob (pulled out) to the desired position. Adjustment range: 355° (i.e.
ALX 73x GB STARTUP AND OPERATION Switching the unit on and off Switching the machine on/off Switching on the unit Move the mains power switch [79A] of the machine to "I" (On). A The machine starts up. Then the dispenser and printer are both in online mode. Switching off the unit Move the mains power switch [79A] of the machine to "O" (Off). [79] Mains power switch (A) on the ALX 73x. The machine shuts down.
ALX 73x STARTUP AND OPERATION Setting and monitoring the dispenser Settings in parameter menu Label pitch A Switch to offline mode B To measure label pitch automatically: Works only up to max. 120 mm label pitch Press and hold the key (for longer than 2 sec- onds). Also possible: enter the label pitch manually: 1. Measure label pitch [80C]. 2. Open function LABEL SETUP > Label pitch. 3. Enter the measured value in millimetres.
ALX 73x GB STARTUP AND OPERATION Label stop position A CAUTION! Mind the following setting rules to avoid a strong decrease of dispensing accuracy: At maximum dispensing speed set the Lab. stop offset to at least 10 mm! a Don´t set Lab. stop offset to the same value as LABEL SETUP > Label pitch (also not to a multiple of the value). Don´t set Lab. stop offset to „0“. Set Lab.
ALX 73x STARTUP AND OPERATION Suppressing start signals The shape of the product or reflecting surfaces can cause a premature start signal, which will result in incorrect labelling. Start signals can therefore be ignored in cases such as these, while the product is being moved along under the dispensing edge. Function LABEL SETUP > Product length must be set to the product length for this purpose.
STARTUP AND OPERATION ALX 73x GB Monitoring functions During labelling operation, the electronic control unit monitors the following functions: Material end / roll diameter (OD = outer roll diameter, PMA = printer, LMA = dispenser) To facilitate quick and smooth changing of the material roll, the machine can send an alarm to operating personnel in advance before the end of the material roll. The OD sensor is used for this purpose. It is available in two designs.
ALX 73x STARTUP AND OPERATION Prerequisites: – External OD sensor is mounted – (LMA) MACHINE SETUP > Ext. OD sensor = "Warning" or „Error“ Message (warning) of the LMA, if the critical OD is reached (MACHINE SETUP > Ext. OD sensor = "Warning") ONLINE OD sensor warn. Message (error) of the LMA, if the critical OD is reached (MACHINE SETUP > Ext. OD sensor = "Error") Status num: 5065 OD Material end If a warning occurs: Label operation continues. 1. Press the key to delete the warning. 2.
ALX 73x GB STARTUP AND OPERATION Setting and monitoring the printer Settings in parameter menu The settings described below are generally included in the print job, in which case they do not need to be made. Manual settings that were made before a print job was transferred will be overwritten by the settings in the print job. For further details on setting options in the parameter menu, see section Printer parameter menu on page 56. Label pitch A Switch to offline mode.
ALX 73x STARTUP AND OPERATION Material type 1. Set PRINT PARAMETERS > Material type to “Punched”. 2. For punched material: Set PRINT PARAMETERS > Light sens. type to “Punched”. for material with reflex markings "Reflex". Print process Set SYSTEM PARAMETER > Ribbon autoecon. depending on which print process is being used (thermal direct or thermal transfer).
STARTUP AND OPERATION ALX 73x GB Ribbon reserve To monitor the ribbon reserve, a critical diameter can be set for the ribbon roll. If the diameter falls below this level, the following message appears: FOIL a a) X JOBS The display flashes. Set SYSTEM PARAMETER > Foil end warning to the preferred ribbon roll diameter in millimetres.
ALX 73x STARTUP AND OPERATION Printing Creating print jobs There are two ways to create a print job: • Layout software + printer driver • Text file with Easy-Plug commands Layout software + printer driver Text file + Easy-Plug Requirement: A printer driver must be installed on the PC. Layout software may include any type of software that has a print function (for example text processing).
STARTUP AND OPERATION ALX 73x GB To send via serial interface (COM1): copy testjob.txt com1 . To send via USB or Ethernet interface: copy testjob.txt \\ComputerName\ShareName , where • ComputerName is the name of the computer (Windows XP: see START > SETTINGS > CONTROL PANEL > SYSTEM > COMPUTER NAME (for example "DM-ECH-0990").
ALX 73x STARTUP AND OPERATION Using product profiles (dispenser) What are product profiles? Product profiles are memory slots in which the complete setting of the dispenser unit can be saved. This makes it possible to adjust the dispenser to a given product quickly for recurring product orders. Number of memory slots: 16 The memory slots are numbered.
ALX 73x GB STARTUP AND OPERATION Saving a product profile Selecting a memory slot Open function MACHINE SETUP > Store prod. prof.. Display if all memory slots are free: Store prod. prof. Prof 1 product 1 If memory slots are assigned, the memory slot that was last active is displayed: Store prod. prof. Prof 5*Customer_xyz A "*" after the memory slot number indicates that the memory slot is already assigned (in this case the profile "Customer_xyz") 1.
ALX 73x STARTUP AND OPERATION Deleting a product profile 1. Open function MACHINE SETUP > Del prod. profil. The last memory slot that was active is displayed. 2. Press the or keys until the required memory slot (1-16) is reached. 3. Press the key to delete the memory slot: Screen: Del. prod. profil Clearing… The product profile has now been deleted.
ALX 73x GB BITTE BEACHTEN Material tear Status messages in case of material tear If the material ribbon tears, one of the following messages appears. Which message appears depends on which spot in the material ribbon is torn. • Dispenser message: Material tear between dispenser and rewinder: Status num: 5140 Rewinder control Material tear at linear dancer arm (see chapter below): Status num: 5070 LDU upper limit • Printer message: Status num: 5002 Material end The machine stops.
ALX 73x OPERATING FAULTS Status messages on the dispenser Error messages When an error occurs, the dispenser stops immediately and shows an error message on the control panel. Error messages are based on the following outline: Status num: 5144 a Rewinder init b a) b) 5144 = The status number. This number is an easy way to identify the message. "Rewinder init" = Status text; brief description of the error. To delete an error message: 1. Rectify the cause of the fault.
ALX 73x GB OPERATING FAULTS Reset warnings A warning is displayed until… • the cause of the warning has disappeared or • the warning has been reset Warnings can only be reset in online mode. If the warning occurs in online setting mode or standalone mode, the user must switch to online mode before resetting the warning. To reset a warning in online mode: Press the key. It is also possible to reset warnings with Easy-Plug command #!CLRW.
ALX 73x OPERATING FAULTS Reference status messages - dispenser List of warnings Rew. stop warn The material rewinder was switched off by the operator. After removal of the rewound backing paper, switch the material unwinder on again. Productstartwarn New start signal during the dispensing cycle. The contour of the product is resulting in multiple start signals. Activate LABEL SETUP > Product length. Several missing labels on the label belt; unable to compensate for the gap.
ALX 73x GB OPERATING FAULTS Module speed The printer is printing too slowly. Start signals must therefore be left out. Increase the print speed or reduce the dispensing speed/dispensing rate. Foil low Critical foil roll diameter at the printer reached. Prepare for foil roll change List of error messages 5000 Bus device This message appears in most cases as the first of a series of two or three messages that more closely limit the source of the error. Unable to access device on the I2C bus.
ALX 73x OPERATING FAULTS 5026 MotorProtect CPU Dust filter fleece dirty. This will cause the machine to overheat. Replace the dust filter fleece. Allow the machine to cool off. Connector cable between CPU board and motor driver board not connected or faulty. Check whether the cable is connected correctly. Check the cable. Motor driver board overheated or faulty Switch off the machine, wait for 30 seconds and switch it on again.
ALX 73x GB OPERATING FAULTS 5070 LDU upper limit The linear dancer lever has reached the upper limit stop. This causes the printer to stop. The material ribbon is torn. Insert new label material. If this error occurs repeatedly reduce the spring tension of the linear dancer arm. Linear dancer lever sensor is not connected. Check the sensor cable. Sensor cable of the linear dancer lever sensor is faulty. Replace sensor cable.
ALX 73x OPERATING FAULTS 5147 Tandemsynch. init Initialization of tandem synchronisation This message can only occur in tandem operation. Communication between master and slave machine is not working. Check the tandem interface cable (cable present and correctly connected?). Check the settings on both machines. 5152 Winding direct. The backing paper was incorrectly fastened on the rewinder core. Fasten the backing paper on the rewinder as described in the operating manual.
ALX 73x GB OPERATING FAULTS 6030 New parameters New firmware has been loaded, which has caused new functions to be added to the menu. Press the online key to confirm. The system is restarted. All parameters are set to the factory setting. 6207 No file card No memory card was found. Check to see whether a memory card is inserted. If the memory card was not inserted until after the machine was switched on: Turn the machine off and on again.
ALX 73x OPERATING FAULTS Status messages on the printer Error messages When a fault occurs, the printer shows an error message on the control panel. Error messages are based on the following outline: Print status a: 5144 b Rewinder init c a) b) c) Depending on the cause of the error, "Print Status" or "Queue Status" appears here. "Print Status" = message from the printer controller; "Queue Status" = message from the Easy-Plug Interpreter. 5144 = The status number.
ALX 73x GB OPERATING FAULTS Reference status messages - printer List of error messages 5001 No gap found The label sensor has not found a label starting mark (punch or reflex marking). Incorrect setting of the material type. Check to ensure the setting of PRINT PARAMETERS > Material type matches the label material you are using. Incorrect sensor type set (SYSTEM PARAMETER > Light sens. type). Check to ensure the set sensor type matches the label material (punches or reflex markings).
ALX 73x OPERATING FAULTS 5008 Foil end In thermal printing: Ribbon end sensor is not switched off. SYSTEM PARAMETER > Ribbon autoecon. = "Thermal printing". In thermal transfer print: Ribbon roll is used up. Insert a new ribbon roll. The core of the ribbon roll is resting loosely on the dispenser. Use a ribbon roll with a suitable core diameter. Adjust the spring plate on the ribbon unwinding mandrel so that the ribbon core is firmly seated.
ALX 73x GB CLEANING Cleaning instructions Safety WARNING! Dangerous situations may arise during maintenance and cleaning work. Accidents may occur due to mechanical or electrical effects if the relevant safety instructions are not observed! Switch off the device before cleaning or maintenance and pull out the mains power connecting line! Never allow liquid to get into the machine! Do not spray the machine with spray bottles or sprays! Use a cloth wetted with cleaning agent.
ALX 73x CLEANING General cleaning Dust particles are especially likely to accumulate in the area of the print mechanics. Remove dust particles with a soft brush or a vacuum cleaner. Clean the housing with a cloth and a standard commercial neutral cleaner.
ALX 73x GB CLEANING Printhead General notes The thermal head [87A] and its holder [87C] are referred to together as the printhead [86]. CAUTION! Danger of irreversible adjustment of the printhead position. A Never loosen the screws [86A] on the printhead. A If a print head ever becomes misaligned, remove the entire printhead and send it in to us for realigning.
ALX 73x CLEANING Cleaning the printhead WARNING! Burn hazard! The printhead can become hot during operation. A Be careful whenever touching the printer. A Paper dust and coloured particles from the thermal transfer ribbon may collect on the printhead during printing. Over time, this can significantly impair the printing quality in the following ways: • Contrast differences in label • Bright strips in printing direction [88] Loosen the wing bolts (A) on the printhead.
ALX 73x GB CLEANING Cleaning with a cleaning stylus Run the stylus many times back and forth across the thermal strip [90A] of the printhead. A [90] Clean the printhead with the cleaning stylus. A Thermal strip Using a cleaning strip Rub the rough side of the cleaning strip [91A] many times back and forth across the thermal strip of the printhead. As you do so lightly press the cleaning strip with your hand. A [91] Clean the printhead with the cleaning strip.
ALX 73x CLEANING Replacing printheads A The printhead can only be replaced as a complete unit as shown in [97A]. A WARNING! Burn hazard! The printhead can become hot during operation. Be careful whenever touching the printer. 1. Switch off the machine. 2. Remove the mains power connecting line. [93] Printhead in the ALX 736. 3. Remove the material and ribbon. 4. Pull out both plugs [95A,B] on the printhead. [94].
ALX 73x GB CLEANING 8. The resistance of the new printhead can be entered using the SYSTEM PARAMETER > Head resistance parameter. The resistance is given on the printhead sticker [97 B]. CAUTION! Entering the wrong resistance can damage the printhead! B A Enter the resistance that is applied against the installed printhead. Testing the printhead [97] Printhead (A) with resistance identification (B), in this case: 1221 Ohm.
ALX 73x CLEANING Rubber rollers Feed rollers/print roller Printer: The feed roller [98A] and print roller [98B] can be cleaned from the bottom of the machine without any additional assembly work. The ribbon roller [98D] is freely accessible while the cover is open and the ribbon is removed. Dispenser: D C A The feed roller [98C] is freely accessible when the label material has been removed. Cleaning the rollers: B 1. Switch off the machine. 2. Remove the mains power connecting line. 3.
ALX 73x GB CLEANING Pressure roller WARNING! Burn hazard! The printhead can become hot during operation. Be careful whenever touching the printer. 1. Switch off the machine. 2. Remove the mains power connecting line. 3. Remove the material and ribbon. A 4. Remove the bolt [99B] (using 3 mm Allen key). 5. Remove guide section [99A] from side. 6. If printhead does not move into position at far left or right of printhead axis: Mark position of printhead on axis. B [99] Remove the guiding section (A).
ALX 73x CLEANING Deviator rollers Glue from the label material may adhere to the deviator rollers. Moisten a clean cloth with cleaning solvent and wipe off the dirty deviator rollers [102] with it. [102]Rubber rollers (dark grey) and deviator rollers (light grey) on the ALX 73x.
ALX 73x GB CLEANING Sensors Clean the sensors regularly to remove any material residue and dust. The cleaning intervals depend on the materials in use. Cleaning the punch sensor To access the punch sensor, first remove the guiding section: 1. Switch off the machine. A 2. Remove the mains power connecting line. 3. Remove the material and ribbon. 4. Remove the bolt [103B] (using 3 mm Allen key). B 5. Remove guide section [103A] from side. 6. Write down the position of the sensor thumb wheel [103B].
ALX 73x CLEANING Cleaning the material end sensor The material end sensor [106A] is located inside the material guide. The sensor must be cleaned of material and dust residue regularly. The cleaning intervals depend on the material in use. Clean the sensor arm using compressed air (canned air is available as an accessory). If the sensor is heavily contaminated, use cleaning solvent and a lint-free cloth to clean the sensor.
ALX 73x GB CLEANING Cleaning the ribbon path All parts which come into contact with the ribbon [107] must be cleaned on a regular basis.
ALX 73x CLEANING Replacing the filter liner CAUTION! A clogged dust filter can result in overheating, thereby causing a machine failure. Replace the filter liner on the fan regularly. The replacement interval for the filter liner must be defined according to the specific circumstances.
ALX 73x GB APPENDIX EC Declarations EC Declaration of Incorporation (translation of original version) We, Avery Dennison Deutschland GmbH Ohmstrasse 3 D-85386 Eching, Germany hereby declare that the incomplete machine designated below has been designed and built in such a way as to be in conformity with the following safety and health protection requirements of Directive 2006/42/EC: Appendix I, item 1.1.2, 1.1.3, 1.1.5, 1.2, 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.4.1, 1.2.4.2, 1.2.4.3, 1.2.4.4, 1.2.6, 1.3, 1.3.
ALX 73x APPENDIX EC Declaration of Conformity (translation of original version) We, Avery Dennison Deutschland GmbH Ohmstrasse 3 D-85386 Eching, Germany hereby declare that we have designed and built the machine designated below so that it is in conformity with the basic safety and health protection requirements of the directive named below: Models ALX 734, ALX 735, ALX 736 General designation Label print dispenser Serial number consists of a consecutive number (5 digits) + date code (YYMM) + end (unit
Avery Dennison Deutschland GmbH Ohmstraße 3 85386 Eching Germany Telephone: +49-8165-925-0 http://www.monarch.averydennison.
