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Avery Dennison ALS 204, Service And Installation Manual

The Avery Dennison ALS 204 is a top-of-the-line labeling solution that ensures efficient service and installation. To help you get started, we offer a comprehensive Service and Installation Manual. Download this manual for free from our website, manualshive.com, to unlock the full potential of your ALS 204.

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3

C

ONTENTS

ALS

20X 

256

1 

Please observe the following

1.1 General information

1.1.1  Validity and applicability of this manual  . . . . . 6
1.1.2  Conventions and information  . . . . . . . . . . . . . 7
1.1.3  Notes on installation and repair work . . . . . . . 8

1.2 Safety instructions

1.2.1  Information and qualifications . . . . . . . . . . . . 10
1.2.2  Machine operating safety . . . . . . . . . . . . . . . 12
1.2.3  Safe operation. . . . . . . . . . . . . . . . . . . . . . . . 13

2 Technical 

Data

2.1 Specifications

2.1.1  Characteristics  . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2  Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3  Label sensor . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.4  Power supply  . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.5  Electronics  . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.6  Interfaces  . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.7  Internal Interfaces . . . . . . . . . . . . . . . . . . . . . 16
2.1.8  Status messages, test functions, product 

profiles  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1.9  Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.10 Environmental conditions . . . . . . . . . . . . . . . 17
2.1.11 Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.12 Certificates  . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Dimension diagrams

2.3 Performance data

2.3.1  Label rate  . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.2  Calculation sheet for performance diagrams  21
2.3.3  Dispensing speed over duration v(t) . . . . . . . 23
2.3.4  Dispensing speed over length v(x) . . . . . . . . 24
2.3.5  Dispensed label length over duration x(t) . . . 25
2.3.6  Performance matrix (ALS 256) . . . . . . . . . . . 26

3 Installation 

and deinstallation

3.1 Unpacking, assembling and 

connecting the machine

3.1.1  Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2  Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.3  Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1.4  Attaching the dispensing edge . . . . . . . . . . .  33
3.1.5  Connecting to the mains power supply  . . . .  35
3.1.6  Connecting the external operator panel . . . .  38

3.2 Connecting the sensors

3.2.1  Photoelectric label sensor  . . . . . . . . . . . . . .  39
3.2.2  Alternative label sensor . . . . . . . . . . . . . . . .  44
3.2.3  Changing light/dark switching at the product 

sensor or the alternativ label sensor  . . . . . .  47

3.2.4  Photoelectric product sensor . . . . . . . . . . . .  48
3.2.5  Photoelectric roll diameter sensor . . . . . . . .  49
3.2.6  Rotary encoder. . . . . . . . . . . . . . . . . . . . . . .  53

3.3 Decommissioning, Dismantling, 

Disposal

3.3.1  Take the machine out of operation. . . . . . . .  56
3.3.2  Dismantling the machine . . . . . . . . . . . . . . .  56
3.3.3  Machine disposal . . . . . . . . . . . . . . . . . . . . .  56

4 Functions

4.1 Function menu

4.1.1  Overview  . . . . . . . . . . . . . . . . . . . . . . . . . . .  57
4.1.2  Notes on the description of functions . . . . . .  59
4.1.3  LABEL SETUP menu . . . . . . . . . . . . . . . . . .  59
4.1.4  MACHINE SETUP menu . . . . . . . . . . . . . . .  60
4.1.5  INTERFACE PARA menu  . . . . . . . . . . . . . .  65
4.1.6  SIGNAL INTERFACE. . . . . . . . . . . . . . . . . .  67
4.1.7  SERVICE/DIAGNOS. menu. . . . . . . . . . . . .  71
4.1.8  SERVICE DATA menu. . . . . . . . . . . . . . . . .  73

5 Operation

5.1  Automatic dispensing speed 

adjustment

5.1.1  Principle of operation . . . . . . . . . . . . . . . . . .  75
5.1.2  Mounting the rotary encoder  . . . . . . . . . . . .  76
5.1.3  Entering the rotary encoder resolution . . . . .  77
5.1.4  Entering the diameter of the measuring 

wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  77

5.1.5  Entering the rotary encoder type . . . . . . . . .  77
5.1.6  Example: Entering the values for the 

recommended rotary encoder  . . . . . . . . . . .  78

5.1.7  Calibrating the belt speed  . . . . . . . . . . . . . .  78
5.1.8 Calculation 

scheme for the automatic 

dispensing speed adjustment. . . . . . . . . . . .  79

Summary of Contents for ALS 204

Page 1: ...ALS 204 206 256 SERVICE INSTALLATION MANUAL Labeller Edition 8 3 2012 Original version ...

Page 2: ......

Page 3: ... 3 Setting up 29 3 1 4 Attaching the dispensing edge 33 3 1 5 Connecting to the mains power supply 35 3 1 6 Connecting the external operator panel 38 3 2 Connecting the sensors 3 2 1 Photoelectric label sensor 39 3 2 2 Alternative label sensor 44 3 2 3 Changing light dark switching at the product sensor or the alternativ label sensor 47 3 2 4 Photoelectric product sensor 48 3 2 5 Photoelectric rol...

Page 4: ... 7 2 Electronics Components 7 2 1 ALS 20X 120 7 2 2 ALS 256 121 7 3 Circuit boards 7 3 1 CPU board 122 7 3 2 Motor driver board 127 7 3 3 Operator panel board 129 7 3 4 Applicator Interface 131 7 4 Power supplies Transformer 7 4 1 Power supply ALS 20X 137 7 4 2 Transformer ALS 20x 139 7 4 3 Power supply ALS 256 140 7 5 Signal Interface 7 5 1 General notes 141 7 5 2 Circuit diagrams for signal inpu...

Page 5: ...wer supply functions 180 9 2 2 Checking output voltages 181 9 2 3 Troubleshooting 183 9 2 4 Checking the power supply 185 9 3 Opening the casing 9 3 1 Removing the dust splash guard 186 9 3 2 For machines held in place by side plate or base plate 188 9 3 3 For machines held from the rear side 189 9 4 Unwind unit 9 4 1 Expanding mandrel 190 9 4 2 Brake 192 9 4 3 Dancer arm 194 9 5 Feed unit 9 5 1 F...

Page 6: ...uipped with various dis pensing edges to suit customer requirements Removal and repair of the dispensing edge are described in a separate service manual Technical State Technical state 10 2011 Software versions Firmware 1 40 Applicator Interface 1 37 Liability Avery Dennison assumes no liability for damages re sulting from improper adjustments or repairs of the ma chine It is assumed that only kno...

Page 7: ...rsonnel The notice contains safety in structions on how to safeguard possibly af fected personnel The instructions must be followed CAUTION A caution notice indicates risks which if unheeded could lead to material damage or bodily injury minor injuries The notice contains instructions on how to prevent damage or injury The instructions must be followed Illustrations When required text passages are...

Page 8: ...parts to come into contact with grease petrol benzene kerosene or mineral oil Environmental protection Avoid unnecessary waste e g use cleaning cloths sparingly and reuse packing material Only store operating materials such as fresh or used cleaning agents in suitable containers Never allow them to enter the sewerage system or to seep into the ground Do not put old batteries removed parts and used...

Page 9: ...one location if possible and into the switch cabinet Twist together unshielded lines from the same cir cuit This reduces interference effects of various kinds Wire inductive components to suitable interference suppressors Possible inductive components Relay solenoid valve Possible interference suppressors Diodes varis tors RC combinations House all components suspected of being sources of RF inter...

Page 10: ...e acquired through technical training in mechanics and electronics for example in Germany the training to become a mechatronics engineer Participation in a technical training course for the corresponding label dispenser offered by the manu facturer The service personnel must be acquainted with the functionality of the label dispenser The system integrator must be acquainted with the functionality ...

Page 11: ...here to all relevant ordi nances and rules in their applicable form Examples Work place regulation Accident prevention regulations Trade union regulations for occupational safety and health Equipment safety law Recycling and waste management law Information must be made available This service guide must be made available to all persons who are ent rusted with installing setting up adjusting or rep...

Page 12: ...Carry out test runs using the task speci fic settings under near production condi tions Only put the machine into operation after at least one successful test run has been completed Protection measures in applicator mode WARNING Danger of crushing between dispenser edge and applicator pressure plate due to applicator movement Prevent personnel from reaching bet ween dispensing edge and applicator ...

Page 13: ...t be pulled off from the machine side power connector If the machine is connected to a cabinet a suitable and accessible power separa tor must be provided by the system inte grator Before any repair work Detach the machine from power supply Check to ensure it is de energised Secure the power supply against uninten tional or unauthorised switch on Casing Before opening the casing pull the power plu...

Page 14: ...imum of 2 persons If possible use a crane or other lifting device Only use suitable and defect free restrai ning devices during transportation and installation Never allow the machine to stand with loosened mounting brackets not even for a short time If the machine is fastened to a movable support Ensure it can not tip over WARNING Risk of accident due to uncontrolled ma chine start up Before doin...

Page 15: ...er Internal rewinding yes Material width including backing paper 3 ALS 204 ALS 206 ALS 256 up to 110 mm up to 160 mm up to 160 mm Label width ALS 204 ALS 206 ALS 256 10 110 mm 10 160 mm 10 160 mm Label length 5 to 600 mm Label roll Winding direction Dispenser outer Ø Rewinder outer Ø Core inner Ø inner or outer up to 300 mm up to 200 mm 38 1 76 2 101 6 mm 1 5 3 4 Distance to peel edge L shape disp...

Page 16: ...uts Inputs Sub D15 optically insu lated optionally via two 8 pin M12 separate in puts outputs in each case 4x PNP 24 V a maxi mum of 500 mA channel total permissible output current 1500 mA 3x PNP NPN 24 V Data interfaces Serial Ethernet USB CF card Control panel interface RS232C Sub D9 max 115 200 Baud 10 100 BaseT RJ45 Device V1 1 USB B Full speed operating mode 12 MBit s Slot for 1 CompactFlash ...

Page 17: ... limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to...

Page 18: ...AGRAMS ALS 20X 256 2 Dimensions of the ALS 20X ALS 256 part 1 74 86 84 330 204 380 206 256 414 204 464 206 256 132 204 182 206 256 111 204 161 206 256 118 60 140 226 431 226 431 173 248 474 75 24 32 298 205 266 471 2 2 DIMENSION DIAGRAMS ...

Page 19: ...19 2 TECHNICAL DATA 2 2 DIMENSION DIAGRAMS ALS 20X 256 3 Dimensions of the ALS 20X ALS 256 part 2 ALS 204 ALS 206 256 341 402 492 488 2 0 5 3 2 0 ...

Page 20: ...ites Direct dispensing without applicator No printer attached Reading example 5 Given a label length of 25 mm including the gap and a dispensing speed of 20 m min a maximum of approx 750 labels per minute can be dispensed The exact value can be calculated with the Calculation sheet for performance diagrams see ch 2 3 2 p 21 5 Reading example of the maximum label rate 2 3 PERFORMANCE DATA ...

Page 21: ... 6 Requires Microsoft Excel or a compatible spread sheet program Enter the the values for max speed and label pitch including gap into the input fields 6A Read the calculation results 6B Inputs max speed Maximum dispensing speed aimed at Must equal the conveyor speed of the production line label pitch including gap Length of one label plus one gap measure from one label start to another Outputs ti...

Page 22: ...bel rate This value can also be determined graphically see 4 Diagrams of performance data Out of the input values the calculation sheet calculates and draws diagrams for the functions v t 7 v x and x t The diagrams show some basic relations which cannot be read as clearly from the calculation results Example 7 With a label length of 26 mm the required max dispensing speed of 40 m min is not reache...

Page 23: ...for the duration of 34 ms B Because a shorter label is used the braking begins just in the moment of reaching the max dispensing speed C In this case the label is even shorter with the con sequence that the max dispensing speed is not reached The braking already begins at a speed of approx 36 m min D The same as A with a lower max dispensing speed ...

Page 24: ...ntact A The diagram shows that already approx 14 mm are dispensed until the max dispensing speed is reached The distance between dispensing edge and pressure roller measures 15 mm dotted lines thus the label reaches the pressure roller with the max dispensing or product speed B In this case the max dispensing speed is reached though only for a moment C In this case the max dispensing speed is not ...

Page 25: ...25 2 TECHNICAL DATA 2 3 PERFORMANCE DATA ALS 20X 256 2 3 5 Dispensed label length over duration x t 10 Example diagrams with different settings for dispensed label lengths over dispensing duration ...

Page 26: ...e Example To reach a label stop accuracy of 0 5 mm with a dis pensing speed of 50 m min the label pitch must be at least 45 mm All values in the chart were measured under the following conditions L shape dispensing edge 155 mm wide Top labelling Label sensor Wenglor OPT242 P800 opti cal NPN Winding direction face out Sensor position to peel edge 19 mm Core diameter 3 Zoll APSF Other label material...

Page 27: ...1 9 N 50x125 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N 80x80 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N 100x100 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N 155x200 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N Fasson 5100 150 180 AA1658 Vellum Extra 45x45 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N 50x125 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N 100x100 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N 155x200 0 5 0 5 0 5 0 5 0 5 0 5 1 9 N Fasson 5400 110 125 PE 85 weiß 45x45 0 5 0 5 0 5 0 5 0 5...

Page 28: ...ons If possible use a crane or other lifting device CAUTION To avoid damaging the machine during un packing Never hold the machine by the deflection rollers dancer arm or rewind or unwind unit Lift the machine out of the packaging with at least two persons To do so hold the machine by its casing After unpacking check the machine for visible ship ment damage Alternatively the machine can be lifted ...

Page 29: ...he following measures Outer diameter 60 mm Wall thickness minimum 5 mm The machines offer three attachment points for mount ing to the support Rear side Requires a fixing bolt to be mounted on the rear side of the machine A joint 16B is used to attach the fixing bolt to the support Advantage The machine can be inclined both side to side and forwards and backwards Side plate Requires a flange 16A t...

Page 30: ...e the two cylinder pins 17B in the holes in the fixing bolt 17A Screw the fixing bolt 18B onto the flange on the rear side of the machine with the screw provided 18C The two cylinder pins must locate into the holes 18A in the flange Mount the fixing bolt with its bevelled side pointing inwards towards the machine Tightening torque 350 Nm 17 Fixing bolt A for clamping the machine from the rear side...

Page 31: ...halves of the head joint 22A with the joint pin 22B as shown Tighten the set screws at the joint axis Slide one half of joint over the trunnion bolt on cy linder on the machine and tighten the screw 22A Observe the warning notice see above Mount the head joint assembly with the clamp pointing side ways or downwards Lift the machine and slide the free end of the head joint over the end of the suppo...

Page 32: ...y 23C in cluding screws and washers A7622 Tool 8 mm hexagon socket driver Screw the flange plate 23C to the side or base of the machine Use the four screws provided in delivery ISO 4762 DIN 912 M10x25 Lift the machine and slide the clamp over the end of the tubing of the support Tighten the set screw 23A Tightening torque set screw 23A 45 Nm Blind hole depth 13 mm 23 Attachment points B C A ...

Page 33: ...ng edge holder so it cannot swivel the pins are located in dia metrically opposite holes By replacing the pins in adja cent holes the mounting angle of dispensing head holder can be adjusted in 15 increments 26 Locate the pins in diametrically opposite holes Choose either inner or outer circle of holes depend ent on angle required Fit the dispensing edge holder onto the pins at the required angled...

Page 34: ...n be replaced by the optional adjustable dispensing edge holder 28 which enables a height adjustment of the dispensing edge Adjustment range 70 mm in steps of 0 2 mm 30 Mounting is possible in different angles in steps of 15 as with the standard dispensing edge holder Article no RH A8018 LH A8138 Adjusting Rotate the adjustment wheel 28A until the inten ded height is reached 30 Adjustment range of...

Page 35: ...ltage selection switch ALS 20X Ensure that the machine is cor rectly adjusted to your local supply volta ge ALS 256 Only operate the machine using the system voltage indicated on the nameplate Only plug machine in to a correctly ins talled socket with an earth contact The length of the power cable must not exceed 3m Only by disconnecting the plug from the mains supply is the machine fully discon n...

Page 36: ...ply voltages for the two positions of the volt age selection switch To change the voltage setting Ensure that the mains power supply lead is un plugged Slide the switch 33A into its other position To do this insert a small screwdriver into the groove 33B and push the red insert horizontally until it stops in the opposite position for case shown in fig 33 to the left Switch position Permitted mains...

Page 37: ... socket ALS 20x with splash guard The power supply cable is connected by installing the splash guard mit Spritzwasserschutz Das Netzanschlusskabel wird durch aufsetzen der Abdeckhutze angesteckt Before installing the splash guard 36A ensure that the machine side power switch 35A is switched on position I the power switch at the splash guard 36B is switched off switch doesn light 35 Power lead B pl...

Page 38: ...factory installed cable Don t extend the cable External and built in operator panel can be used alter nately Connect the external operator panel to the mini DIN connection 38A Mounting the external operator panel Tool Cross head screwdriver medium size Drill 2 holes according to the drawing beside 39 Arrows Open the operation panel housing 4 screws Mount the lower part of the housing using 2 M4 sc...

Page 39: ...A101972 Sensor with bracket 40 A101971 Connection cable 1 5 m Connecting the photoelectric sensor Plug the photoelectric label sensor in to the connec tor shown 42A Pin assignment 43 Pin assignment for photoelectric label sensor connection Pin Assignment 1 24 V 2 LED 3 Ground 4 Sensor signal 40 Avery label sensor standard since 9 2011 41 Wenglor label sensor OPT242 P800 old standard until 9 2011 4...

Page 40: ...on diagram 44 Connection diagram for photoelectric label sensor The LED current at pin 2 controls the sensitivity of the sensor 24V 1 2 4 3 0 20mA 24V Label gap detection signal NPN input NPN output Label signal LED current GND Label sensor Current feed back signal LED current setting ...

Page 41: ...ndow opens for 2 8 s During this period the status LEDs are flashing fast 46 While the LEDs are flashing move as many labels as possible at least 2 through the sensor fork This has to be done manually not by pressing the button If the labels were detected successfully the status LEDs are flashing 2x 47 If the labels were not detected ideal the status LEDs are flashing 4x Repeat the procedure if th...

Page 42: ...s LEDs 48B flash 2x Finding out the current setting Move some label material through the sensor fork and watch the LEDs Compare the result with the table 49 Overview LED activity and output levels with or without Label Mode Label LED Output Wenglor NPN Yes On Low No Off High Avery PNP Yes On High No Off Low Avery NPN Yes Off Low No On High 48 Switching the Avery sensor between PNP and NPN PNP NPN ...

Page 43: ...contrast it can be necessary to adjust the label sensor manually Call up MACHINE SETUP Sensor Adjust Display Place backing paper in the fork of the photoelectric sensor Press the key until the LED 50A on the photo electric sensor lights up Press the key and keep it pressed just beyond the point where the LED goes out Note the displayed value value 1 Place label material in the fork of the photoele...

Page 44: ... by calling the function MACHINE SETUP Label sens type The setting is stored within the product profile Connecting the sensor Plug the sensor in to the connector shown 51A ALS 256 51B Pin assignment 1 chapter Changing light dark switching at the product sensor or the alternativ label sensor on page 47 Connection accessories Article no Connector cable Ø 4 6 mm A8142 Connector cable Ø 6 8 mm A8143 C...

Page 45: ...agon socket drivers 4 6 mm Turn out screw 53C and remove the dispensing edge 53E Remove the screws from the bottom ends of the hol ding rods Take off the dispensing edge holder 53D Push the sensor holder 53A onto the holding rods and fix it with the thumb screw 53B Reinstall dispensing edge holder and dispensing edge Connect the cable 24V 24V NPN Configuration NPN Signal PNP Signal PNP Configurati...

Page 46: ... LED The LED 54C must shine in label gaps If case of insufficient switching behaviour change the sensitivity setting After increasing the sensitivity setting the base ad justment must be repeated See www leuze de Di Soric sensor setting Insert label material into the sensor fork The label material must lie on the bottom fork arm 55D Press the button 55C until the mode LED 55B yellow lights up appr...

Page 47: ...pes is the absolute rule Leave jumper JP 901 respectively JP 902 open Example The alternative label sensor pictured in 54 has an in verse output on pin 2 Therefore JP 901 must be left open 1 With the board in the pictured position 57 Controlling pin2 at the sensor connector by placing JP901 resp JP902 JP 901 JP 902 Function 1 Pin 2 of the sensor connector is not connected default setting 1 Pin 2 o...

Page 48: ...ng light dark switching at the product sensor or the alternativ label sensor on page 47 Connection Diagram 60 Connection diagram photoelectric product sensor Pin Assignment 1 24 V 2 24 V or ground or no connection 1 3 Ground 4 Sensor signal 58 Recommended photoelectric product sensor A Connection cable Article no A7127 B Data sensor S51 PA 5 C10 PK Article no A7112 59 Connection for photoelectric ...

Page 49: ...deviation roller 61C shim ring s and inner lock washer Remove reflector 62A and mounting bracket 62D from the sensor holder Remove the mounting block 62C 2 screws Move the sensor holder 62B behind the dancer arm with the upper end first and position it as illus trated 61 Push the mounting block onto the deviation roller axle and screw it to the sensor holder Push the shim ring which came with the ...

Page 50: ...ional applicator interface see chapter Pin assign ment for machine status connection on page 163 Pin assignment 64 Pin assignment for photoelectric OD sensor connection Connection diagram 65 Connection diagram photoelectric RD sensor Pin Assignment 1 24 V 2 not used 3 Ground 4 Sensor signal 63 Connection for roll diameter sensor A 1 2 3 4 24V 24V Signal PNP input 3 8k 1k Signal GND 1 4 3 2 10k Sen...

Page 51: ...or to the upper 66B or lower 66A position long holes according to the measured roll diameter tab Retighten the thumb screws Insert the prepared label roll Loosen the thumb screws at the sensor 67C Rotate the sensor to the top until the light beam does not meet the reflector any more The LED at the sensor is off Slowly rotate the sensor down until the light beam meets the reflector The LED at the s...

Page 52: ...pensed Additionally the following signals will be activated The message disappears immediately if the light beam stops falling on the reflector Note the following when connecting to the applicator interface No status message will be displayed on the opera tion panel in case of low material only the OD sen sor signal will be activated If no sensor is connected the output signal OD sensor remains ac...

Page 53: ...1K1R61N 00500 Order no 121194 See www pepperl fuchs com Suitable measuring wheel 68A Type 9109 10 Order no 045565 Suitable mounting 68B Type 9213 Order no 045492 Avery Dennison article number for the above mentioned encoder including measuring wheel and mounting A7770 Alternative encoder type Manufacturer Sick Stegmann Type DKS40 E5J00500 and DKV60 E1K01000 See www sick stegmann de Nominal voltage...

Page 54: ... in to the connector shown 69A No changeover is necessary for a Push Pull ro tary encoder Connecting the recommended rotary encoders to an M12 connector Recommended connector Manufacturer Franz Binder GmbH Order no 713 1 99 1429 812 04 See www binder connector de Pin Colour of wire Pepperl Fuchs Colour of wire Sick Stegmann Function 1 Brown Red 24 V 2 Grey Pink Impulse B 3 White Blue Ground 4 Gree...

Page 55: ...TALLATION AND DEINSTALLATION 3 2 CONNECTING THE SENSORS ALS 20X 256 Connection diagram 72 Connection diagram rotary encoder 24V 24V Signal A Signal B 3 8k 3 8k 1k Signal A Signal B GND 1 4 2 3 PNP PP Input CPU ...

Page 56: ...footwear Acute risk of injury and long term bodily in jury from working with heavy loads Lift or carry the machine with a minimum of 2 persons If possible use a crane or other lifting device CAUTION To avoid damaging the machine during transport Never hold the machine by the deflection rollers dancer arm or rewind or unwind unit Let the machine be held by at least 2 persons while a 3rd person loos...

Page 57: ...mode Store prod prof Label sens type Interface Ethernet speed Dispense speed Del prod profil Labelsen InType Spooler mode MAC Address Slew speed Dispense counter Startsen In Type 9 Dispenser ID no SNMP Agent Label pitch Disp Cnt Reset Start disp mode Spooler size SNMP password Lab stop offset Turn on mode Start error stop Offline mode FTP server Start offset Language On inhibit enter Interface del...

Page 58: ...ngth CF CARD SLOT Blow on time 12 Status signals Dispencing cycl Card in slot Restart delay Operation time Position timeout 13 ACTIVE INPUTS MEMORY DATA Apply comp time Start signal POWERSUPPLYDATA Ram memory size Inhibit signal Type Flash mem size OD sensor signal Version CompactFlash 18 Serial number Default values PS Temperature Standby On time 9 Only appears if Interface mode PLC signals 10 On...

Page 59: ...ction Feed speed during initialisation Adjustment range ALS 204 1 0 40 0 m min default 1 0 ALS 206 1 0 30 0 m min default 1 0 ALS 256 1 0 50 0 m min default 1 0 Label pitch function Label pitch label length gap Adjustment range 5 0 600 0 mm default 100 0 mm Lab stop offset function Stopping position of the label at the dispensing plate Adjustment range 0 0 999 9 mm default 20 0 Start offset functi...

Page 60: ... missing labels LABEL SETUP Miss label tol is exceeded machine stops error message error signal active Stop count mode function Settings Enabled Disabled Enabled The dispense counter counts down from the value set in LABEL SETUP Label stop quan When the counter reaches 0 no further labels are dispensed Disabled The labeller counts up i e each label dispensed increases the counter reading Label sto...

Page 61: ...n production mode should only be adjusted by a trained servicing techni cian Default values function Settings Standard User defined Standard Calling the Factory settings parameter sets all parameters to the values defined by the manufacturer User defined All current parameter settings are adopted as default values Calling the Factory settings function then restores these values even after loading ...

Page 62: ...ring wheel of the rotary en coder used Adjustment range 0 0 200 0 mm default 64 0 Appears only if MACHINE SETUP Speed Adaption On See Entering the diameter of the measuring wheel on page 82 Display The diameter of the measuring wheel is shown on the left The current product speed as calculated by the machine appears on the right If this speed is not equal to the actual speed the setting for the me...

Page 63: ...gs Pulse falling Level low active Pulse rising Level high active Pulse fall rise Pulse falling Dispensing a label is triggered by a change from high to low at the sensor signal input Level low active Setting is only visible in production mode Labels are dispensed for as long as the signal at the sensor signal input remains at the value low Pulse rising Dispensing a label is triggered by a change f...

Page 64: ...nsing edge Delete registered starts The queue is deleted Incoming start signals are registered Materialend err function Refers to the internal OD control Settings Disabled Mat diam x mm Setting range for x 40 0 500 0 Default setting x 60 Deactivating the function Set x 40 Re activating the function Press the key Defines the diameter threshold for the material roll If the calculated material roll d...

Page 65: ...master and slave ma chine Therefore the interface function may not be set to Automatic or to Serial Com 1 Spooler mode function Settings Single print job Mult print jobs Dispenser ID no function Labeller identification number Adjustment range 0 31 Sets the identification number of the labeller The la beller can then be called with the interface com mand An n labeller ID Setting up ID numbers is pa...

Page 66: ...r message is displayed Submenu NETWORK PARAM General rules for entering addresses To change to the next previous alphanumer ic character Press the or key To confirm selection and move to the next position Press the key Alternatively inputting can be carried out via the WEB Server function See Web server on page 95 IP Addressassign function Settings Fixed IP address DHCP Fixed IP address This setti...

Page 67: ... page 95 WEB display refr function Defines the time after which the web server display is refreshed Adjustment range 0 20 s default 5 s WEB admin passw function Changes the admin password for the web server default admin Access rights to functions are equivalent to those in supervisor mode see MACHINE SETUP Access author iz WEB supervisor p function For changing the supervisor password for the web...

Page 68: ... a setable length of time After the run out of this application time the applicator moves back into home position PEP Blow on PEP type applicator with blow on function After run out of the application time the blow on function is activated After run out of the blow on time the applicator moves back into home position PEP II Sensor The cylinder movement is limited by a touchdown sensor which signal...

Page 69: ...nal Dedicated signal output Pin 5 at the signal interface Adjustment range 1 99999 ms default 200 ms LA TO Timed 500 ms Blow on time function Appears only if SIGNAL INTERFACE APPLIC SIGNALS Applicator type PEP Blow on ASA Reverse PEP BTS O ring applicat or LA BO Sets the duration for blowing on of each label Only appears when an applicator that requires blow ing on is used e g PEP Blow on Dedicate...

Page 70: ...start mode Depending on the selected mode the start signal will be interpreted differently Settings Pulse fall ris Level high activ Pulse rising Level low active Pulse falling Pulse fall ris The dispensing of a label is triggered by a low high change as well as by a high low change of the start signal The dispensing occurs only after the set delay time Level high activ Labels are being dispensed a...

Page 71: ...Disabled The AI is completely disabled Enabled The applicator control of the AI is disabled Enabled are the status outputs at the machine status connector and the Airstream support output at the applicator connector Submenu ACTIVE INPUTS In this menu the active input signals can be selected if there are identical input signals at different interfaces This can e g be the case with some signals at s...

Page 72: ...displayed under SERVICE DATA CPU BOARD DATA Serial number Data blocks del function Deletes one or all data blocks in the flash memory Appears only if at least one data block is in the flash memory Settings Bxx All Bxx Deletes block number xx After calling the parameter data block number 01 is displayed B01 block number 01 diagnose inf name of the data block is contained in the data block header If...

Page 73: ...the mileage of the drive roller Maximum value 4 Bn metres Dispencing cycl function Counter for the number of labels dispensed Operation time function Displays the total amount of time the machine has been switched on Submenu POWERSUPPLYDATA Type function Displays the type of power supply Version function Shows the power supply version Serial number function Shows the power supply serial number PS ...

Page 74: ...he remote operator panel Remote disp function Shows the serial number of the remote operator panel Submenu CF CARD SLOT Card in slot function Tests whether the CF card is located in the slot in the machine Result Yes The CF card is in the slot Result No No CF card is in the slot Submenu PERIPHERAL DATA Applicator int function Function only appears when there is an applicator interface installed Sh...

Page 75: ... synchronisation thanks to the automatic speed adjust ment If the conveyor belt stops while a label is being dispensed the label feed will also stop If the conveyor belt starts up the label feed will be activated automati cally The speed of the conveyor belt is picked up by a rotary encoder 78 A and transmitted to the control system of the labeller The rotary encoder is not included in the scope o...

Page 76: ...HINE SETUP Encoder Diameter Rotary encoder at the motor axle The rotary encoder is mounted onto the motor axle The rotation speed of the motor is normally transmitted via a reduction gear to the driving axle of the conveyor belt The reduction ratio of the gear motor axle rotates fas ter than drive axle must be considered when entering the rotary encoder data This can be done on two ways Entering a...

Page 77: ...signal signal A is utilized Advantage less expense as with double phase Disadvantage Lower resolution as with double phase If the conveyor is standing still vibrations can produ ce faulty signals which the labeller cannot distin guish from real signals Double phase normal operation Many rotary encoder produce a second signal signal B which is out of phase by 90 Using this sig nal can overcome the ...

Page 78: ...Set MACHINE SETUP Speed Adaption to On 5 1 7 Calibrating the belt speed After the function MACHINEN SETUP Encoder Diameter has been called the following is displayed x x diameter of measuring wheel yy y belt speed according to current measurement var indicates variable belt speed If the actual belt speed is known the measured speed can be synchronised with it as follows Increase or decrease the di...

Page 79: ...nputs p sensor pulses Number of pulses which delivers the rotary encoder per rotation Typical values 100 up to 5000 pulses rotation d wheel diameter Diameter of the measuring wheel or of the conveyor drive wheel depending on the mounting option of the rotary encoder See Mounting the rotary enco der on page 76 Typical values up to 200 mm m step mode Depending on the sensor features and the labeller...

Page 80: ...igital filter for noise suppression If the specific output frequency of the rotary encoder is lower than this value must be entered here xlimit min resolution Minimum admissible resolution referred to the con veyor belt distance which must be measurable The resolution should be at least 0 2 mm to avoid significant deterioration of the dispensing accuracy on the product climit run length counter Th...

Page 81: ...n As a rule unlabelled products can be prevented At the idle machine the operator has the option to re load with new label material or to eliminate minor mal functions The first machine in the production line is designated as the master device the second is designated as the slave device Normally the master device is activated first Flipflop master mode The master machine can be set to master mode...

Page 82: ...es must be set for the use of the rotary encoder The product sensor is connected to both machines using the Y cable 85 Tandem interface cable for synchronisation over Com1 Article number A7978 or standard network cable for synchronisation over Ethernet interface 85 Y cable for start sensor connection A7979 99 1429 812 04 0 75 m 0 7 5 m Coupling Plug Plug brown 1 white 2 blue 3 black 4 1 brown 2 wh...

Page 83: ...o peer that is direct connection without network Connect the crossover network cabel to the ether net interface 87C on both machines If both machines are connected to a network standard 1 1 network cables are required for connection brown yellow metal cover or metallized plastic cover metal cover or metallized plastic cover shielded cable UL style white brown green yellow brown green white yellow ...

Page 84: ... communication between master and slave machine Therefore the interface function may not be set to Auto negotiation or to Serial Com1 INTERFACE PARA COM1 PORT Baud rate 115 200 No of data bits the same setting on both machines Parity Stop bits Data synch None MACHINE SETUP Tandem synchron Serial Com1 Master MACHINE SETUP Tandem Operation Master or FlipFlop master Tandem Distance Set the distance 8...

Page 85: ...andem synchroni sation via Ethernet interface Settings on Menu Submenu Function Setting Master and Slave INTERFACE PARA EASYPLUGINTERPR Interface TCP IP SOCKET MACHINE SETUP Tandem synchron UDP Tandem Port Master MACHINE SETUP Tandem Operation Master or FlipFlop master Tandem Distance Set the distance 91A between the dispensing edg es of the master and slave Slave IP address 127 000 000 001 INTERF...

Page 86: ... message appears This message appears when communication between the master and slave is interrupted If the slave is switched on first the message does not appear On master Display in master mode Display in flipflop master mode The machine is ready for operation and begins la belling once it receives a signal from the product sensor On slave Display Display alternates between this and standard dis...

Page 87: ... by the distance be tween the two machines A fine adjustment of the label position at the slave is possible during operation Change to operation mode Online settings 92 Set the offset value using the two buttons 92A B on the right half of the operation panel This modifies the label position on the product 92 Operation panel in the Online settings mode ON STATUS Speed 12 2 fix Offset 0 0 A B ...

Page 88: ... Stopping continuing labelling On the active machine Press the key Display 2 Or Online FF Master or Online Slave This has no effect on the second machine To continue labelling Press the key Status Master Slave Master is labelling Online Master 1 Labels xxx Online Slave Dispenser locked Material end at master slave starts labelling Statusnum 5002 Materialende Online Slave Labels xxx Acknowledge err...

Page 89: ...g applicators are available for the ALS 20x 256 LA TO tamp on applicator 94A LTP LTPV tamp on applicator for variable product heights and or sensitive products 94B LA BO blow on applicator 94C WARNING Danger of crush injuries at LTP LTPV and LA TO Only operate LTP LTPV and LA TO with higher level protective equipment see service manual LTP LTPV or service ma nual LA TO The applicators are controll...

Page 90: ...nctions of the real operator panel E Starts the FTP server in a new browser window See FTP server on page 94 F Input field for user name Preset admin G Input field for password Preset admin The password can be changed under INTERFACE PARA NETWORK PARAM WEB server H Click on this button after entering user name and password I Displays the machine model J Displays the firmware version K Links to the...

Page 91: ...mance application of the dispenser Prerequisites Labeller is connected to network A valid IP address is assigned to the dispenser by the network administrator or by a DHCP server INTERFACE PARA NETWORK PARAM WEB server must be set to Enabled Starting the web server Note down the IP address of the labeller This is shown under INTERFACE PARA NETWORK PARAM IP address Start internet browser Enter the ...

Page 92: ... on the Save button The value is now transferred to the labeller 96 Example Dialog box for entering value for the function LABEL SETUP Start offset Some functions trigger a reset of the labeller if they have been changed on the labeller via the operator panel However if any of these func tions is changed via the web server the reset does not occur automatically The changes only come into effect af...

Page 93: ...he virtual operator panel The buttons 98B D underneath the virtual operator panel are equivalent to key combinations on the real operator panel A Offline button Sets the machine offline during dispensing mode Equals pressing the button B View switch button Switches into standalone mode required for loading firmware see Loading from memory card auf Seite 95 Equivalent to the combination C Reset but...

Page 94: ... PARA NETWORK PARAM FTP server must be set to Enabled FTP client is installed on the host computer The FTP connection is not blocked by a firewall The following FTP clients are enabled for com munication with the internal FTP server GNU Midnight Commander 4 6 0 OS Linux WS FTP Pro 5 0 OS Windows NT Windows 95 Microsoft Internet Explorer IE 5 0 5 5 6 0 OS Windows NT Windows 95 Starting the FTP serv...

Page 95: ... waits for confirmation from the user before starting CAUTION If a firmware file was saved with the exten sion FOR it will be loaded without first re questing confirmation Always save firmware files with the exten sion S3B Select file as described above Press the key Display Press the key Display Press the key The firmware download starts without any further as sistance accompanied by the display ...

Page 96: ...FAXES by right clicking on the device icon then clicking PROP ERTIES SHARING The Share name stands for a printer that is connected to a certain port a USB port for transfer via USB or the TCP IP port for Ethernet transfer Some tips about transfer via a USB or Ethernet interface The procedure described does not work with Windows 98 Windows ME or Windows NT 4 0 The Share name must satisfy MS DOS con...

Page 97: ...to a memory card Switch the labeller off Insert memory card into labeller s card slot Switch the labeller on Call MACHINE SETUP Store Parameters This function only appears in the menu if there is a memory card in the labeller s card slot Choose an option for saving With adjust para or Without adj par With adjust para Preset device specific settings are included in what is saved These include senso...

Page 98: ...uitable files in the FORMATS directo ry or no memory card in the card slot the following message appears Loading procedure Select file as described above Press the key Display Top line selected file name The loading can take a couple of seconds To visualize the progress the point is moving during the loading The configuration is loaded after the restart 6 3 4 Automatic loading Save the configurati...

Page 99: ...mmand prompt window showing the command to transfer the file setupall for to the interface Com1 USB Ethernet interfaces On the host computer Open a command prompt window Enter the command copy setupall for Computerna me Share name replace setupall for with your file name where Computername Name of the computer You can find this name in Windows XP under START SET TINGS CONTROL PANEL SYSTEM COM PUTE...

Page 100: ...Start print mode Pulse falling PC2051 1 G Language English PC2053 0 G Access authoriz Deactivated PC6010 41 G Sensor Adjust Manual 41 PC6005 0 G Speed Adaption Off PC6006 0 G Encoder Type Single Phase PC6008 500 G Encoder Resol 500 pulses turn PC6009 64 0 G Encoder Diameter 64 0mm 13 0var PC6040 1 G Rewinder Operat Enabled PC6018 0 G Tandem Operation Disabled PC6020 0 G Tandem Synch None PC6038 0 ...

Page 101: ... G WLAN 64Bit Key 2 123456789a PC1525 123456789a G G WLAN 64Bit Key 3 123456789a PC1526 123456789a G G WLAN 64Bit Key 4 123456789a PC1517 123456789ABCD123456789ABCD G G WLAN 128BitKey 1 123456789ABCD123456789ABCD PC1518 123456789ABCD123456789ABCD G G WLAN 128BitKey 2 123456789ABCD123456789ABCD PC1519 123456789ABCD123456789ABCD G G WLAN 128BitKey 3 123456789ABCD123456789ABCD PC1520 123456789ABCD123...

Page 102: ...d data G G readonly ID 30034 G CPU identifier 25 0 G readonly ID 30036 G PCB Revision REV03 G readonly ID 30037 G FPGA version 9617 G readonly ID 30039 G MAC Address 000A 44 04 00 1D G readonly ID 30040 G Serial number A637105450041 G readonly ID 30041 G Production date 11 11 2005 G readonly ID 30042 G PCB part number A6371 03 G readonly ID 30043 G Board part numb A6378 03 G readonly ID 30044 G Ma...

Page 103: ...06 0 1207 1 1501 0 1501 0 1501 0 1501 0 1505 9100 1506 0 1521 0 1522 public 1507 0 1508 avery 1509 0 1510 5 1511 admin 1512 supervisor 1529 0 1530 2105212662 1531 3600 1513 ALS_204_RH_04001D 1514 avery 1515 0 1516 1 1523 123456789a 1524 123456789a 1525 123456789a 1526 123456789a 1517 123456789ABCD123456789ABCD 1518 123456789ABCD123456789ABCD 1519 123456789ABCD123456789ABCD 1520 123456789ABCD123456...

Page 104: ...commands n Machine ID is set using INTER FACE PARA EASYPLUGINTERPR Dis penser ID no PG Function ID G PGn Gives readout of menu function set tings via the interface that is set up for use 107 Function ID identification number of menu function n 1 2 4 8 16 32 xx PB s n Function ID Value Function ID Value G Value assignment to one ore more functions in a product profile s number of the product profil...

Page 105: ...ormat ERRxnnnn LF nnnn Status number belonging to the status message Examples or return strings ERR00000 Currently no active status message no active message in the past ERR05002 Currently no active status message in the past the Material end message 5002 was ac tive which has already been acknowledged ERRU5145 Currently the Rewinder full mes sage 5145 is active The message must be ack nowledged b...

Page 106: ...ne specific settings are not included in the information sent 2 Values for machine specific settings e g sensor adjustment values are not commented out 107F Machine specific settings are consequently transferred along with the rest of the settings when these are sent to another labeller 4 Additional output of comments These comprise the name and value of the function in text form Besides this a nu...

Page 107: ...orm Meaning Example Integer i 0 2147483647 1 0 minimum value 2147483647 max value 1 Increment MACHINE SETUP Dispense counter Float f 5 0 600 0 0 1 5 0 min value 600 0 max value 0 1 Increment LABEL SETUP Label pitch String s 32 32 max string length INTERFACE PARA NETWORK PARAM DHCP host name Discrete d 0 Disabled 1 Enabled LABEL SETUP Stop count mode A1 G Machine Setup for ALS 204 RH Version V1 01 ...

Page 108: ...00 Function ID of the function LABEL SETUP Dis pense speed 10 0 Speed in m min The MACHINE SETUP Store Parameters function saves all parameters along with their function IDs and current values to the CF card as a text file 999999 Function ID for Special functions must be used together with one of the values listed below Example A PC999999 1 G Resets the machine 109 Values for PC Value Function 1 R...

Page 109: ... Dispense counter 2065 n 0 16 Loads product profile no n A va lid product profile must be stored under this number After the com mand a restart is executed LABEL SETUP Load prod profil 3213 n 0 10000 ms Signal delay after dispense end SIGNAL INTERFACE PLC SIGNALS Disp end delay 6000 f 0 0 MAX m min Dispensing speed LABEL SETUP Dispense speed 6001 f 0 0 MAX m min Slew speed LABEL SETUP Slew speed 6...

Page 110: ...emory 111 Bits in the return string of WARF Bit Meaning 0 New start signal during the dispensing ope ration or Several missing labels on the web which can not be compensated 2 Material low 4 The conveyor speed exceeded the max speed of the dispenser 5 OD control sensor detected material end 6 Too many products between sensor and dispensing edge max 8 products are allowed 7 The rewinder is deactiva...

Page 111: ...he button to change to yes Press the button All settings in the functions menu are deleted inclu ding the setting which caused the firmware to crash Switch the machine off Switch the machine on while keeping the buttons pressed until the machine type is dis played After this display press the following buttons in succession 3x Set the machine type under MACHINE SETUP Dispenser type Switch the mach...

Page 112: ...g a diagnose dump is done either automatically if the machine got in an undefined state or manually by pressing all four operation panel buttons simultaneous ly Events which trigger an automatic storing of the diag nose dump Dispensing suddenly stops Status message unmanaged interrupt appears on the display The device suddenly doesn t react on keystrokes any more A diagnose dump can be accessed on...

Page 113: ...port of the PC and click OK The window COM1 Properties 114 opens if COM1 was selected Set the transfer parameters to 115 kB n 8 1 and click OK The Hyperterminal main window opens Open the menu Transfer and click Record Text 115 An input window opens Enter the file name for the record file and click Start At the printer operation panel press all four buttons simultaneously This starts data being re...

Page 114: ...56 Transfer Record text Generating further record files Close Hyperterminal and start new 116 Read out data Send the generated files with a description of the cir cumstances in which the error occured per email to the technical support at Avery Dennison ...

Page 115: ... DATA CPU BOARD DATA Serial number Press the button twice to acknowledge and to store the file name Typing in a new file name Press the button to dismiss the default file name Select each character of the new file name by pres sing the or buttons and acknowledge it by pressing Finally press the button twice to acknowledge and store the file Alternatively type in the file name on an optional key bo...

Page 116: ...A8132 A6627 A7679 A7777 A7778 A6803 A6379 A7389 A7060 A7068 A6727 A6727 A6727 A6727 A6727 A5001 A6805 A4455 A6571 A7620 A6801 A6804 A6802 110V 230V 75V 17V 5V 24V 24V Motordriver board CPU board Applicator Interface Accessory Material end sensor Operation panel Sensors rewinder dancer Feed motor Rewinder motor Transformer Power supply 7 ELECTRONICS DESCRIPTION 7 1 WIRING DIAGRAMS ...

Page 117: ...LABEL OD APSF A7301 A7950 A8132 A6627 A7679 A7777 A7778 A6803 A6379 A7389 A7060 A7068 A6727 A6727 A6727 A6727 A6727 A8734 A8171 A7620 A6801 A6804 A6802 5V 24V A8463 A8464 A8734 24V 75V 17V Motordriver board CPU board Material end sensor Operation panel Sensors rewinder dancer Feed motor Rewinder motor Power supply ALPS 600 Fan ...

Page 118: ... PLC IN START LABEL OD APSF A7301 A7950 A8132 A6627 A7679 A7777 A7778 A6803 A6379 A7389 A7060 A7068 A6727 A6727 A6727 A6727 A6727 A5001 A6805 A8734 A4455 A8171 A7620 A6801 A6804 A6802 A8463 A8464 Motordriver board CPU board Applicator Interface Accessory Material end sensor Operation panel Sensors rewinder dancer Feed motor Rewinder motor Power supply ALPS 600 Fan ...

Page 119: ...cer Arm Position light barrier encoder Unwinder Rotation material diameter Pressure Roller Material Motor stepper motor motor power digital sensor digital sensor bi phase counter OXHILQ 38 RDUG switched mode power supply 5V 3A 24V 2A dual Stepper motor Driver 54V 12V 24V 38 RDUG with ELW PLFURFRQWUROOHU and 9 VLJQDO LQWHUIDFHV signals USB remote Display toroid transformer 443 VA m ains AC 5V 24V g...

Page 120: ... of casing removed A Toroidal transformer B CPU board C Operator panel D Photoelectric sensors to determine position of re wind unit dancer arm E Stepper motor for the rewind unit F Motor driver G Connections for sensors PLC inputs outputs H Stepper motor for the label feed I Power supply unit A B C D F E G H I 7 2 ELECTRONICS COMPONENTS ...

Page 121: ...omponenten des ALS 256 Rückhaube ausgebaut A CPU board B Operator panel C Photoelectric sensors to determine position of re wind unit dancer arm D Stepper motor for the rewind unit E Motor driver F Connections for sensors PLC inputs outputs G Stepper motor for the label feed H Power supply unit A C E D H G F B ...

Page 122: ...CRIPTION 7 3 CIRCUIT BOARDS ALS 20X 256 7 3 1 CPU board Connections and configuration 123 Connections on the CPU board A6379 A B C D E F G H I J K L M N O P Q R S T U V W Y Z AA AB AC AD AE AF AG X AI AH 7 3 CIRCUIT BOARDS ...

Page 123: ...r additional motor driver optional N CN 808 Sensor connection for internal roll diameter control O CN 809 Connection for pressure roller switch optional P CN 703 Connection for power supply I2 C bus Q CN 801 Motor driver connection R CN 807 Connection for dancer arm sensor 1 optional S CN 806 Connection for dancer arm sensor 2 optional T CN 805 Connection for dancer arm sensor 3 rewind unit U CN 7...

Page 124: ...ION 7 3 CIRCUIT BOARDS ALS 20X 256 Preset jumper positions If a defective CPU board has to be replaced Set or remove the jumpers on the new board as shown 124 124 CPU board These jumpers on the board must be connected or removed ...

Page 125: ...125 7 ELECTRONICS DESCRIPTION 7 3 CIRCUIT BOARDS ALS 20X 256 Layout diagram 125 Layout diagram for the CPU board ...

Page 126: ... 5V 24V remote display mini DIN 6 display JTAG Debug JTAG I2C Bus Buffer V24 Driver RS232 Ethernet PHY 38 LW IDT RC32355 PQFP 208 Reset Flash ROM 4 MBytes SDRAM 16 MBytes Configuration Interrupts EEPROM 256Bytes 3 Altera Cyclone EP 1C3 T144 TQFP 144 PCB version Jumper Address Data Bus Ethernet magnetics display interface RS422 485 3 x Light Barrier Sensor 3 x Light Barrier Sensor quadrature home s...

Page 127: ... F D 201 Status LED red rewinder motor G D 202 Status LED red feed motor 128 Meaning of the status LEDs D 201and D 202 H D 405 LED green lights if the 3 3 V supply voltage is connected I D 203 green lights if the 75 V supply voltage is connected J F 401 Fuse T 0 5AH 250 Original part when delivered from factory Littelfuse Series 215 K CN 401 Transformer connection L F 402 Fuse T 6 3 A 250 Original...

Page 128: ...128 7 ELECTRONICS DESCRIPTION 7 3 CIRCUIT BOARDS ALS 20X 256 Layout diagram 129 Layout diagram for motor driver board ...

Page 129: ...nections A CN 2 Programming adapter connection Only for factory internal use B CN 4 Connection for cable to key C Connecting cable to key D CN 5 Connection for cable to key E CN 1 I O Board connection Layout diagram 131 Layout diagram for operator panel 130 Operator panel assy A6627 B D E A C ...

Page 130: ...U 70 ATmega 168 20AU 16kBytes Flash TQFP32 DB 0 7 LCD RS LCD RW LCD E 5V 5V 1 6 5 4 3 2 RS485 transceiver SP491E UART RXD UART TXD 5V 5V 1 2 H 6 main board connector JST B6B PH K S 5V UART TXEN 4k7 4k7 470R 470R line termination 8 57 N DXG power supply connector Molex 53047 0210 Display 128 x 32 dots Y A 21 67 786 OD PP IN PP PP PP IN IN IN PP PP IN VCC GND RST Program Debug SPI H 83 H 2 H 2 1 LCD...

Page 131: ...following table Finding out the currently installed firmware version SERVICE DATA MODULE FW VERS If the AI firmware doesn t match the CPU firmware the following message appears Load the correct firmware see Loading Firmware auf Seite 101 Updating AI boards is earliest possible with change index 02 Firmware CPU Firmware AI 1 01 1 17 1 02 1 10 1 18 1 33 1 23 1 40 1 37 Status num 5212 Vx x for AI rec...

Page 132: ...pplicator B CN 602 Signal interface machine status C CN 401 Connection product start sensor D Light guides which lead the LED signals from the plug on board a to the boards mounting panel E CN 402 Internal connection product start sensor F CN 610 Internal signal interface machine status G CN 101 Connection CPU board A B C H I J D K O L a G E F M N ...

Page 133: ...Default settings for the jumpers JP 101 104 and JP 202 I CN 102 Debug interface J CN 604 Connection power supply K CN 605 not used L SI 601 Fuse T1A 250V M D 331 Green LED only for factory internal use N D332 Yellow LED only for factory internal use O CN 609 Internal connection applicator JP104 JP103 JP102 JP101 JP202 ...

Page 134: ...134 7 ELECTRONICS DESCRIPTION 7 3 CIRCUIT BOARDS ALS 20X 256 Layout diagram 135 Layout diagram for Applicator Interface PCB A3417 03 ...

Page 135: ...ternal applicator A_OUT 1 8 A_IN 1 6 P_IN 1 3 M_IN 1 2 M_OUT 1 7 Internal product light barrier Internal maschine status External maschine status External applicator Reset Steuerung RESET Externer Reset TxD_0 RxD_0 APSF AI_IRQ H8_IRQ TxD_1 RxD_1 Programmier Debug Schnittstelle zur CPU Platine USI Port uC Extern Produktlichtschranke Isolationsbarriere Status Ausgänge M_OUT 1 7 A_OUT 1 8 Sensor Eing...

Page 136: ...out the board rack until the connections at the rear end of the CPU board are accessible Connect both cables to the CPU board and to the Applicator Interface see Ch 7 1 Wiring Diagrams page 116 Plug the Applicator Interface board onto the spread sockets 139A at the board rack Reinstall the board rack While doing so pay atten tion that the noses at the rear end of the board rack fit into the holes ...

Page 137: ... cable E Fuse holder for fuse F1 T5AH 250 V F Fuse holder for fuse F2 T5AH 250 V Siehe Fuses auf Seite 138 G Voltage selection switch 115 230 V Pin Description 1 2 24 V 3 4 24 V Ground 5 6 5 V 7 8 5 V Ground 9 24 V In Out In put 10 Power Fail Out put Pin Description 1 Neutral lead 2 110 V AC 3 230 V AC 140 Connections on the A6571 00 power supply unit A C D E F G B 1 3 5 7 9 10 8 6 4 2 1 2 3 7 4 P...

Page 138: ...d with the mains supply Contact with energised components can result in life endangering currents through the body as well as burns Ensure that the machine is switched off and that the power cable is unplugged be fore you remove the fuse holder CAUTION Danger of fire if the wrong types of fuse are put in Only replace fuses with the type specified in this manual Tools Screwdriver Switch off the mac...

Page 139: ...20X 256 7 4 2 Transformer ALS 20x 142 Transformer connectors 143 Transformer windings 1 2 3 SEC PRI 1 2 3 4 white yellow red blue black 12V white 0V white 53V white 0V white 0V black T1 110V blue T2 230V red T3 Thermal fuse 130 C 10A 250V Thermal fuse 130 C 10A 250V ...

Page 140: ...tential are not connected Checking the power supply Remove the power supply At connector C connect the pins 5 and 9 to enable the power supply Make sure that at least the following currents are drawn before measuring the output voltages Logic 5 2 V 200 mA Motor 17 V 10 mA Measure the output voltages Pin Description 1 17 V 2 17 V Ground 3 75 V 4 75 V Ground Pin Description 1 5 2 V 2 NMI 3 SCL 4 SDA...

Page 141: ...face mode PLC signals Applicator signals SIGNAL INTERFACE Interface mode Applic signals Recommended connector Avery article no A8144 male A8145 fem Manufacturer Franz Binder GmbH Order no 713 1 99 1487 812 08 See www binder connector de 7 5 2 Circuit diagrams for signal inputs 148 Main circuit for signal inputs NPN 149 Main circuit for signal inputs PNP 145 Position of the signal interface A 146 P...

Page 142: ...s the label against the appli cator plate Active after the start signal until start of application cylinder Vacuum Output Controls the vacuum at the appli cator plate Active after the start signal until end of application cylinder Blow On Output Controls the blow on valve of the applicator Active after end of application cylinder Duration setable with SIGNAL INTERFACE APPLIC SIG NALS Blow on time ...

Page 143: ...nterface For details about applicator types read the de scription of function SIGNAL INTERFACE APPLIC SIGNALS Applicator type on Seite 58 Signal Applicator LTP V PEP IV PEP Blow on PEP II Sens ASA Rev PEP Direct Dispense BTS O Ring appl LA BO LA TO timed LA TO sensor Inputs Home Position X X X X X X X X X Touch Down X X X X Out puts Airstream Support X X X X X X X 2 X X X X Vacuum X 1 X X X X X Cy...

Page 144: ...mined by label length and dispensing speed Airstream Support switching to low means the label is dispensed B Can be adjusted via Dwell time Duration t is determined by the backwards movement of the applicator The application cycle ends when the home position signal is high again C The output signal Offline follows the input signal Inhibit D The start signal is ignored because of the active Inhibit...

Page 145: ... is setable by Dwell time t2 is setable by Blow on time see note C C Can be adjusted with Blow on time D Duration t3 is determined by the backwards movement of the applicator The application cycle ends when the home posi tion signal is high again E The output signal Offline follows the input signal Inhibit F The start signal is ignored because of the active Inhibit t3 t1 t2 Start signal Airstream ...

Page 146: ...cycle ends when the home posi tion signal is high again D The output signal Offline follows the input signal Inhibit E The start signal is ignored because of the active Inhibit F The end of Cycle can be adjusted with Dwell time usual ly this function sets the end of the Cylinder signal in case of the Reverse PEP Cylinder stays active up to the next start signal what means that the dwell time is ig...

Page 147: ...tion t is determined by the backwards movement of the applicator The application cycle ends when the home posi tion signal is high again C Adjustable with Blow on time D The output signal Offline follows the input signal Inhibit E The start signal is ignored because of the active Inhibit t Start signal Home position Airstream support Cylinder setable Vacuum Blow on setable Offline Cycle Inhibit To...

Page 148: ... Duration t is determined by the backwards movement of the applicator The application cycle ends when the home position signal is high again C Adjustable with Blow on time D The output signal Offline follows the input signal Inhibit E The start signal is ignored because of the active Inhibit t Start signal Home position Airstream support Cylinder setable Vacuum Blow on setable Offline Cycle Inhibi...

Page 149: ...ns the label is dispensed B Duration t is determined by the backwards movement of the applicator The application cycle ends when the home position signal is high again C The output signal Offline follows the input signal Inhibit D The start signal is ignored because of the active Inhibit t Start signal Home position Airstream support Cylinder setable Offline Cycle Inhibit Touch down Additional sig...

Page 150: ...rn of control signals over time for ASA applicators A Duration is determined by the label length and dispensing speed Airstream Support switching to low means the label is dispensed B Can be adjusted via Blow on time C The output signal Offline follows the input signal Inhibit D The start signal is ignored because of the active Inhibit Start signal Airstream support Vacuum Blow on setable Addition...

Page 151: ...nd dispensing speed Airstream Support switching to low means the label is dispensed B Can be adjusted via Blow on time C The output signal Offline follows the input signal Inhibit D The start signal is ignored because of the active Inhibit Additional signals available with optional Applicator Interface Start signal Airstream support Blow on setable Cycle Inhibit Offline A C D B ...

Page 152: ...out 500 mA 1 Error Output Signal active when an error message appears on the opera tor panel display Iout 500 mA 1 Dispense End Output Signal that can be used to acti vate a secondary unit e g a printing unit Signal length and delay can be set via the function menu Iout 500 mA 1 Warning Output Active if a warning status occurs e g label roll diameter below desired nominal value Iout 500 mA 1 162 P...

Page 153: ...d delay 165B C Period setable via SIGNAL INTERFACE PLC SIGNALS End pulse width 165C D Signal modes setable via SIGNAL INTERFACE PLC SIGNALS End dispense mod 165D Modes high low active The signal is activated with the start of dispensing The duration is the sum of the three periods A B C Modes high low pulse The signal is activated after dispensing ended and after period B and it lasts period C 165...

Page 154: ...1 and A1B2 A relative position of the product sensor at the time of rising signal slope A relative position of the dispensing edge at the time of rising signal slope B relative position of the product sensor at the time of dropping signal slope B relative position of the dispensing edge at the time of dropping signal slope Function Setting Abbrev Signal slope Effect MACHINE SETUP On inhibit enter ...

Page 155: ...e causes the queue to be deleted Two of the products are matching both conditions in this case the impact of the dropping slope counts 168 Example of setting combination A2B1 A B A B Start signal Inhibit signal Product sensor Dispensing edge Product will be labelled Product will not be labelled A B A B Start signal Inhibit signal Product sensor Dispensing edge Product will be labelled Product will...

Page 156: ...ELECTRONICS DESCRIPTION 7 5 SIGNAL INTERFACE ALS 20X 256 169 Beispiel Kombination A2B2 A B A B Start signal Inhibit signal Product sensor Dispensing edge Product will be labelled Product will not be labelled ...

Page 157: ...lows for the connection of an external operator panel See Connecting the external operator panel auf Seite 38 USB 172 Pin assignment for USB interface Suitable connection cable to a PC USB cable A B Article number 126738 Pin Signal 1 4 6 connected 2 RxD 3 TxD 5 Ground 7 RTS 8 CTS 9 not used Pin Signal 1 Vcc from the host detec tion if a connection is exist ing 2 Data 3 Data 4 Ground 170 A RS 232 i...

Page 158: ...2 00 49 or 00 0a 44 02 00 49 The first three bytes are always 00 0A 44 Avery identifier the last 3 bytes vary from device to device Manufacturers are responsible for assigning MAC addresses to the devices they make IP address The labeller firmware implements a TCP IP protocol stack which means that the labeller needs an IP address for the network in addition to its MAC ad dress IP addresses are al...

Page 159: ...re requested from the DHCP server Address net mask default gateway During the request process a device name is communicated to the DHCP server to assist the system administrator This name is made up of the model of labeller 3 characters from the MAC address Example ALS_204___020049 It is not necessary to connect to a name server This is where to set the IP parameters in the labeller function menu ...

Page 160: ...r kit Article no A5069 contains connector and connector housing for each 1x D Sub 15 high density 1x D Sub 26 high density 1x D Sub 44 high density 7 7 2 Circuit diagrams for signal inputs For each signal input are 24 V and GND 24 V sepa rately available 177 Main circuit for signal inputs NPN 178 Main circuit for signal inputs PNP 179 Switching level definitions for signal inputs 1 With 3 8 mA inp...

Page 161: ...f one or several outputs the respecti ve outputs are pulsed until the overcurrent condition is removed During this the output current is limited to 400mA During an error case each quad channel power switch sets a diagnosis signal which is detected and sent to the CPU by the microcontroller 7 7 4 Power outputs Power outputs can directly drive loads 182 Admissible loads at power outputs Maximum admi...

Page 162: ...ation cylinder Blow On Power output Iout 500 mA Controls the blow on valve of the applicator Active after end of application cylinder Duration setable with SIGNAL INTERFACE AI BOARD SIG NAL Blow on time BTS Power output Iout 500 mA Controls the Bad Tag Separator BTS Active if a bad RFID tag is detec ted Is set back by the following action e g devaluating the bad tag 184 Applicator connection arrow...

Page 163: ...or is activated This setting can be changed with SIGNAL INTERFACE ACTIVE INPUTS Start signal Home Input Iin 6 mA Active if the applicator has reached the home position appli cation is finished Touch Down Input Iin 6 mA Use with sensor controlled appli cators e g LTP Active if the applicator touches the product Repeat Input Iin 6 mA Same function as start signal Feed Input Iin 6 mA Feeding of the l...

Page 164: ...art signals are ignored while signal is active CAUTION Initially this signal in put is deactivated The Inhibit sig nal input at the standard signal interface is activated This setting can be changed with SIGNAL IN TERFACE ACTIVE INPUTS Inhibit signal 187 Machine status connection arrow 188 Pin assignment machine status connection 189 Position and pin assignment of the internal machine status conne...

Page 165: ...Initially this signal in put is deactivated The OD sen sor in standard signal input M12 connector is activated This set ting can be changed with SIGNAL INTERFACE ACTIVE INPUTS OD sensor signal OD sensor Power output Iout 500 mA Active if the input OD sensor is set high Offline Power output Iout 500 mA Active in configuration mode Not active in dispensing mode Inverted Ready signal Signal name Func...

Page 166: ...f Seite 162 Key Mechanic coding of the connector reverse polarity protection Reserved Input not applied Iin 6 mA 190 Product sensor connection arrow 191 Pin assignment product sensor connection 192 Position and pin assignment of the internal product sensor connection CN 402 A Start K 24 V GND Key Reserved Reserved A K Key K A 24 V GND n c 24 V GND 1 2 3 4 5 11 12 13 14 15 6 7 8 9 10 Start K 2 24 V...

Page 167: ...als auf Seite 156 R e s e r v e d o u t R e s e r v e d o u t B l o w O n o u t B T S o u t A i r s t r e a m S u p p o r t o u t V a c u u m o u t C y l i n d e r o u t F e e d i n R e p r i n t i n R e s e r v e d i n T o u c h D o w n i n H o m e i n S t a r t i n O f f l i n e o u t O D s e n s o r o u t n o t u s e d o u t C y c l e o u t R e a d y o u t W a r n i n g o u t E r r o r o u t O ...

Page 168: ...warning is active at a time the highest prioritised warning appears at first if thit one is set back the next one appears and so on 8 1 4 General software errors The occurrence of errors in the firmware can never be completely precluded These types of errors are given the name general software error in the error directory They can only be corrected by the manufacturer If an error listed as a gener...

Page 169: ...face receive error COM1 Overrun Press the key to ack nowledge 3001 RS232 Parity RS232 interface receive error COM1 Parity Press Online button to acknowledge Check setting in labeller s function menu INTERFACE PARA COM1 PORT Parity and on host computer 3002 RS232 Frame RS232 interface receive error COM1 Frame Press Online button to acknowledge Check the setting in the labeller s function menu INTER...

Page 170: ...necessary Press the key to confirm the er ror message 5002 Material end Material end if the internal OD con trol is activated Insert new label roll 5009 Start error Refers to the standard start sensor input M12 The device received another start signal while applying a label Prerequisite MACHINE SETUP Start er ror stop is set to On Check the operation of the labeller increase distance between produ...

Page 171: ...t CPU ALS 256 Dust filter liner exhausted This leads to overheating the ma chine Cable between CPU board and Mo tordriver board not properly connect ed or defective ALS 20X Voltage selection switch set faulty Motordriver board overheated or defective Renew the dust filter liner Let the machine cool down Check connection Check cable Check setting of the voltage selection switch Switch the machine o...

Page 172: ...position of the rewinder dancer arm could not be found Check if the sensor board of the dan cer arm is connected properly Replace the sensor board 5143 Rewinder Stop This message appears when the dancer arm was held against its up per stop for more than two seconds Effect Power to the rewinder motor is switched off so that the rewinder can be turned easily by hand This effect is helpful when in st...

Page 173: ...drel Wrong machine type selected MA CHINE SETUP Dispenser type Attach the backing paper web to the rewinding mandrel as described in the user manual Setting RH at a LH machine or vice versa 5200 Home position This message may appear when operating the applicator The ap plicator did not reach its home position upper end position within the intended time frame Applicator operation set but no appli c...

Page 174: ...face AI Check connections 5212 Vx x for AI rec Wrong firmware for applicator interface AI installed Install AI firmware version x x 5250 PLC Out overload At least one PLC output signal is over loaded Possible causes Load to big Wrong wiring CPU board defective Reduce load Correct wiring Replace CPU board 5251 PLC 24V missing 24 V supply for PLC is missing Possible causes 24 V cabling between power...

Page 175: ... have been added to the menu Press the Online button to confirm Automatic reset is performed All parameters are reset to their fac tory settings 6031 Param checksum The parameter checksum is incorrect 6200 Filesystem regis General software error that can occur when installing file system Switch the machine off wait 30 se conds and switch it back on 6201 File sys format Error while formatting RAM d...

Page 176: ...e operated as part of a network Contact technical support Replace the CPU board if necessary 9009 Temporary MAC Temporary MAC address This error is displayed if the MAC address of the CPU board has the value 00 0a 44 00 00 00 In this case the network can be initialised This MAC address is only used during manufacture of the labeller Press the online button to acknow ledge the status message The la...

Page 177: ...o the current board revision Check and modify download data Restart machine 9103 Invalid firmware Download data is incompatible to the current board Check and modify download data Restart machine 9104 Inv data size The size of download data exceeds the predefined size which is set in the header Check and modify download data Restart machine 9107 Flash overflow Onboard flash memory is full Restart ...

Page 178: ...change between 1 and 0 00 03 Capaci capacitive label sensor 1 or 0 Move label material through the sensor a gap between labels punch must cause a change between 1 and 0 00 04 Diamet external photoelectric RD sensor 1 or 0 Breaking the light beam must cause a change between 1 and 0 00 05 APSF f rotary encoder frequency xxx Hz Shows current rotary encoder frequency when labeller operating with autom...

Page 179: ...x yyy xxx Value of absolute dancer arm posi tion dancer arm not initialized The difference between the positive and nega tive value in the respective end positions is approx 40 yyy State of the dancer arm light barriers 0 blocked 1 open 00 16 PLC IN 00000xxx Status display for the signal interface inputs The last three digits xxx show the status of the three inputs PLC_IN1 PLC_IN2 and PLC_IN3 1 Si...

Page 180: ...machine CPU to store important parameter settings For this purpo se a sufficient voltage supply is available If this out put doesn t work properly the settings in the function menu are not stored Power supply fan The speed controlled fan provides active cooling of the power supply If the fan is defective the 24 V 17 V and 75 V voltage outputs are switched off Temperature sensor The power supply is...

Page 181: ...or panel green Green LED 199A next to the D Sub connector at the CPU board connector plate D502 Green LED 200A next to the 10pin connector at power supply D204 Green LED 201A near the 10pin connector on the CPU board D502 indicates 2 5 V which are gener ated out of 5 2 V 199 LED A indicating correct logic voltage at the CPU board 200 LED A indicating correct logic voltage at the power supply A A A...

Page 182: ...U board D901 17 75 V motor voltage A running power supply fan indicates that 17 75 V are available The following LEDs indicate that the motor voltage applies properly 75 V Green LED 204B next to the small inductor on the motordriver board D203 17 V Green LED 204A next to the big inductor on the motordriver board D405 indicates 3 3 V which are generated out of 17 V 202 LED A at the CPU board indica...

Page 183: ...t doesn t work correctly Replace power supply Power fail input at the CPU board doesn t work correctly Replace CPU board 24 V and 17 75 V output voltages are switched off approx 10 s after switching on Rotation speed of the power supply fan is being controlled If the power supply fan is defective or if the speed control doesn t work correctly the outputs 24 V and 17 75 V are switched off approx 10...

Page 184: ...rmore the Warning output is activated both earliest with firmware 1 33 The machne does not stop If the warnng is ignored and no steps are taken to decrease the temperature the outputs 24 V and 17 75 V are switched off as soon as a critical over temperature is reached The logic voltage for the CPU is kept upright An error message appears on the display The ma chine stops earlilest with firmware 1 3...

Page 185: ...connect the pins 5 and 9 to enable the power supply Make sure that at least the following currents are drawn before measuring the output voltages 5 V output 300 mA Logic 200 mA Motor 10 mA Measure the output voltages 205 Pin assignment connector C 206 Connections at power supply A8171 10 8 6 4 2 1 3 5 7 9 Housing A A C D E B ...

Page 186: ...river SW 2 5 and 3 Unscrew four screws 207A arrows Remove the cover box 207A off carefully By doing so the power connector on the inside of the cover box is removed If the cover box for interfaces 207B is prevailing If prevailing Pull the Ethernet connector off from the cover box Unscrew four screws 207B arrows Remove the cover box 207B carefully While doing so unplug the interface cables from the...

Page 187: ...ially pay attention to Check the sealings 208A F for damages and re place them if necessary Put the sealing cords 208A D in the appropriate grooves Fix the sealing cards with instant glue if necessary 208 Gehäuse with dust splash guard Positions of the sealings A G and cover boxes H I A E H C B F G I D ...

Page 188: ...late or base plate 209 The machine is de energised Tools Hexagon socket driver SW 2 5 Remove 11 screws 210 Completely remove the two part casing rear wall ALS 256 Disconnect fan cable The installation is performed in reverse order 210 Fastening screws on rear wall of ALS 20X casing small picture ALS 256 209 Label dispenser ALS 20X held in position via flange attached to base plate ...

Page 189: ...halves of the casing rear wall ALS 256 Disconnect fan cable The installation is performed in reverse order During the installation pay particular attention to the following actions The 4 short screws are for the joint between the two halves of the casing rear wall 212 squares 212 Positions of the screws to be removed from the casing rear wall 211 Label dispenser held in position via the fixing bol...

Page 190: ...rformed in reverse order During the installation pay particular attention to the following actions Grease the sliding surfaces of the expansion bars before installing Removing unwinding spool Remove core adapters 213A Remove three screws 214B on the front side of the sleeve 214A Fully unscrew knob 214C complete with sleeve by turning it to the right left hand thread Remove front O ring 215B Remove...

Page 191: ...to the expanding mandrel 219 Allow the adhesive bond to set Installing the unwinding spool Install unwinding spool with brake loosened Install shim 220B and retaining ring Ensure that the circlip fully engages with the groove in the shaft Measure the axial play of the unwinding spool on the shaft Desired nominal play c 0 2 mm If necessary remove circlip and readjust axial play using a suitable shi...

Page 192: ...y adjusted swivel dancer arm antic lockwise about 20 The brake shoes must open and allow free rotation of the expanding mandrel 222E Install support disc and core adapters The retaining screws 222D on the rotary axles of the brake shoes are screwed into square nuts 223B The square nuts are located in a recess in the steel brake flange and brace against its side 223arrow There is therefore no need ...

Page 193: ... may fall backwards out of flange Ball bearing 225A may fall out of brake shoe Carefully fit new brake shoe Do not touch brake li ning surfaces 225arrow with bare hands and keep the surfaces free of grease Be careful of bolt 225B and ball bearing 225A Install circlips and tension spring Release brake by swivelling dancer arm and install expanding mandrel Set play at the brake cam see previous page...

Page 194: ...ker Loctite 648 adhesive 226 Removing toroidal transformer is not required with ALS 256 Completely removing dancer arm Open the casing see Ch 9 3 Opening the casing Remove unwinding spool see Ch 9 4 1 Expanding mandrel Disconnect the plug connections 226C E Loosen the cable fasteners remove the cable from its guides 226D ALS 20X Remove nut 226B steel disc rubber discs and toroidal transformer 226A...

Page 195: ...remove cable bushing Remove 2 screws 230C on lever plate 230A Remove shaft complete with brake Disconnect plug connection 231C on unwind unit sensor Remove 2 nuts 231B remove the unwind unit sen sor together with its PCB 231A 231 Disconnecting plug connection and removing unwind unit sensor 228 Disconnecting plug connection removing bushing 229 Dancer arm removed from machine A Brake B Shaft C Unw...

Page 196: ...ring screws 233D with Loctite 243 Follow the threadlock ma nufacturer s instructions for use Insert cable bushing with O Ring 232A from the in side and screw tight Grease the brass bushing 235C and guideway in the control lever 235B well When doing so ensure brake linings remain free of grease Fix control lever in correct mounting position Secu re the brass bushing in the marked position in the da...

Page 197: ... the bearing seats Installing the bearings Fixing the ball bearings with adhesive Glue the ball bearings into the bearing seats with Loctite 648 Follow the adhesive manufacturer s instruc tions for use Glue in ball bearing 238A flush with contact sur face 238 surface shaded grey in dancer arm Push in spacer ring Glue second ball bearing 238C into the dancer arm The ball bearing should be pushed in...

Page 198: ...cable bushing with O Ring 240A from the in side of the dancer arm and screw tight Grease the brass bushing 242C and guideway in the control lever 242B well When doing so ensure brake linings remain free of grease Fix control lever in correct mounting position Secu re the brass bushing in the marked position in the dancer arm casing 242A 242 Mount control lever in its prescribed mounting position 2...

Page 199: ...m into casing Ensure that the pin 245B on the front side of the casing mates with the hole 245A in the lever plate Machine with IP65 option check the seal between dancer arm and housing for damages and replace it if necessary Connect plug connection 243A for unwind unit sensor 243 Fitting bushing connecting plug connector 244 Cleaning the shaft s internal thread 245 Pin must mate with hole A B A A...

Page 200: ...transformer and all other components around it Pay particular atten tion to the distance from the power supply unit ca sing 247B ALS20X Slide on second rubber disc and steel disc Screw toroidal transformer into place with nut 248A ALS20X Connect the plug connections 248B D Fit cable into guides 248C and secure with cable fasteners Install unwind spool and adjust axial play of unwind spool on shaft...

Page 201: ...ng measurement of tractive force Hook on force measurement device 249 Pull on the force measurement device until the dan cer arm swivels and the brake releases Specified value for pulling force 8 10 N Adjust restoring force as required Turn the adjusting screw 250A on the dancer arm left to increase restoring force Turn the adjusting screw 250A on the dancer arm right to decrease restoring force 2...

Page 202: ...under certain circumstances tear off or expand in a way which results in poor label ling precision In those cases it is adviseable to install weaker dancer arm springs If the following creteria apply to the label material the Narrow label kit should be installed Less than 50 mm label width Weak or expandable stretchable backing paper 252 Overview Article numbers of dancer arm springs 1 only availa...

Page 203: ...e support disc 256 Remove those 3 screws which are not marked with locking varnish and remove the support disc 256 Support disc at the ALS 256 A Screw marked with locking varnish B Screw without locking varnish to be removed Unhook and remove the tension spring 255A 253 Removing the core adapters 254 Removing the support disc fig ALS 20X 255 Tension spring A at the brake mechanism A A B A A B ...

Page 204: ...der 261A Pull the spring holder downwards 258 262 Remove the spring 259 Installation The installation is performed in reverse order After the installation pay particular attention to the following ac tion Adjust the restoring force 260 of the dancer arm see Ch Adjusting restoring force of dancer arm on page 201 261 Plug the hex socket screwdriver A into the set screw B at the spring holder and pus...

Page 205: ...ws 265A that secure motor driver board in place Remove motor driver board 264C and disconnect all 4 plug connections 264D Loosen 3 screws on the motor 264A to slacken the toothed belt 264F Loosen 2 setscrews on the large pulley 264E Remove pulley and toothed belt Remove circlip 266C and shim 266B Fold pressure roller out of working position Pull the feed roller and shaft 266A out of the ca sing 26...

Page 206: ...ing the mounting mandrel 269 Glue the ball bearings into the casing The ball bea rings should be pushed in until they meet the spacer rings Allow adhesive joint to set fully before installing the feed roller Installing feed roller Smooth dents in the shaft 270arrow with an oilsto ne as necessary Lightly grease the part of the feed roller shaft that has contact with the bearings 271B but keep the f...

Page 207: ... approx 1 5 mm behind the shaft end Tighten setscrew 272B to bevel then tighten se cond setscrew Slide the motor 274A until the toothed belt is taut Tighten 3 screws on the motor mount Connect and install the motor driver board 274D Fasten motor lead to housing with cable fastening 274E Install casing rear wall 9 5 2 Drive Adjusting toothed belt tension Open the casing see Ch 9 3 Opening the casin...

Page 208: ... plug connections 275D Loosen 3 screws on the motor 275A to slacken the toothed belt 275F Mark the installation positions of the pulley 275E on the shaft using a drawing point for example Loosen the two setscrews on the pulley Remove toothed belt along with pulley Loosen 3 fastening screws on the motor and remo ve motor 275 Removing toothed belt and pulley 276 Removing the fastening screws that se...

Page 209: ...belt pulley Turn the belt pulley in order to align one of the two setscrews 278B with the bevel in the motor shaft 278arrow Aligning belt pulley and toothed belt with motor pini on The toothed belt must run in the centre of the belt pulley and motor pinion ALS 256 The belt pulley is positioned further out side on the shaft approx 1 5 mm behind the shaft end Tighten setscrew to bevel then tighten s...

Page 210: ...led thumbscrew 281A all of the way out and remove the pressure roller along with clam ping ring Push out the friction bearing bushings 282A Push the friction bearing bushings into the pressure roller with the mounting mandrel Thoroughly grease friction bearings The lubrication pockets 282arrow in the friction bearing bushings must be completely filled with grease Install the pressure roller Clean ...

Page 211: ...eel roller Allow the adhesive bond to harden fully Place steel roller with washer discs in pressure roller assembly and slide in the axle 285D with the con tact surfaces 285arrows for the pressure pins fa cing backwards Grease pressure pins springs and setscrews and install them in the pressure roller Ensure that the pressure pins mate with the contact surfaces on the axle 286arrow Screw the setsc...

Page 212: ...in place Remove motor driver board 288B and disconnect all 4 plug connections 288C Remove screw 289A Clean thread Screw in the screw using Loctite 243 Threadlock Follow the threadlock manufacturer s instructions for use Before threadlock hardens rotate the support axle to the correct position and tighten the screw Connect and install the motor driver board Fasten motor leads to housing with cable ...

Page 213: ...110 mm ALS 206 Measurement A 160 mm Auxiliary materials Loctite 480 adhesive Loctite 243 Threadlocker Multi purpose grease Removing the spool hub Remove the countersunk screws 291B on front ends of the cone follower inserts 291A Remove the cone follower inserts Remove one of the synthetic binders 292 Remove the spool hub segments 293 A t 4 20 8 30 20 291 Removing cone follower inserts 292 Remove s...

Page 214: ...talling the expansion mechanism Grease the hollow shaft inside and out Push the expansion mechanism onto the carrier shaft and fit the key Fix the front cone 295C in the correct mounting posi tion only necessary if expansion mechanism was dis assembled The grooves in the two cones must be exactly aligned Align the cone with the adjust gauge 295A and screw it flush to the front end of the hollow sh...

Page 215: ...ter 20 Adjust gauge see Fig 290 Hot air blower Mounting mandrel make this yourself to the specifications in Fig 297 297 Mounting mandrel for spacer rings in casing Auxiliary materials Loctite 648 adhesive Loctite 243 Threadlocker Multi purpose grease Removing the dancer arm Remove expansion mechanism see Ch 9 6 1 Expanding mandrel Remove the three screws 299A remove the sup port disc 299B Open the...

Page 216: ...crews 302B and remove the perfora ted plate 302A Remove circlip 302C and shim 302D Pull out dancer arm 301B forwards complete with shaft 301A Be careful of shim and dancer arm spring 301E Pull shaft out of dancer arm Smooth dents in the shaft 302arrow with an oilsto ne as necessary B A D C C D E 302 Removing the perforated plate D A B C ...

Page 217: ...er ring is available press in ball bearing flush with surface Allow adhesive joint to set fully before installing the dancer arm Replacing ball bearings in casing Prerequisite Dancer arm is removed Carefully soften up the adhesive bond on both bea rings 304A using a hot air blower Remove ball bearings and spacer rings 304B Remove adhesive residues from the bearing seats Fixing the ball bearings wi...

Page 218: ...and push shaft complete with dancer arm all the way in Inside the casing slide shim 308E over end of shaft and install circlip 308D Ensure circlip enga ges fully with groove Check the axial play of the shaft in the casing approx 0 2 mm If necessary remove shaft and readjust using a sui table shim Installing the perforated plate Guide the perforated plate 308A into the photo electric sensor 308C Wh...

Page 219: ...ligning belt pulley and toothed belt with motor pini on The toothed belt must run in the centre of the belt pulley and motor pinion Tighten setscrew 310B to bevel then tighten se cond setscrew Slide the motor 310D until the toothed belt is taut Tighten 4 screws on the motor mount 310A Installing remaining parts Install casing rear wall Install support disc 311A When doing so make sure the assembly...

Page 220: ...efully introduce the photoelectric sensor with bracket into the machine casing Take care that the perforated plate 313A does not damage the photo electric sensor Screw in the screws 313C with Loctite 243 thread lock Checking the mounting position of the photoelectric sensor Move the dancer arm The perforated plate must not rub against the pho toelectric sensor Fit shims as necessary to adjust posi...

Page 221: ...river board in place Remove motor driver board 317A and disconnect the plug connections 317B to E Loosen 4 screws on the motor mount 315A to sla cken the toothed belt 315C Mark the installation positions of the pulley and mo tor pinion on their respective shafts using a drawing point for example Loosen 2 setscrews on the large pulley 315B Loosen 2 setscrews on the motor pinion 315F Remove toothed ...

Page 222: ...othed belt and pulley Place the toothed belt 320B over the motor pinion 320A Slide belt pulley 320E onto dancer arm shaft and pull belt onto belt pulley Turn the belt pulley in order to align one of the two setscrews with the bevel in the dancer arm shaft 320Arrow Aligning belt pulley and toothed belt with motor pini on The toothed belt must run in the centre of the belt pulley and motor pinion Ti...

Page 223: ......

Page 224: ...Avery Dennison Deutschland GmbH Ohmstraße 3 85386 Eching Germany Tyskland Alemania Saksa Allemagne Germania Duitsland Alemanha 49 8165 925 0 http www monarch averydennison com ...

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