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Novexx Solutions ALS/XLS 204, Service & Installation Manual

The Novexx Solutions ALS/XLS 204 is a state-of-the-art printer that delivers exceptional printing quality and efficiency. To ensure seamless installation and optimal performance, users can easily access the Service & Installation Manual. Download this comprehensive manual for free at manualshive.com, providing step-by-step instructions and invaluable insights for users.

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Service Manual  

ALS/XLS 20x/256/272

03/2019 | 03

75

Installation and Deinstallation

Exchanging the 

unwinder

 springs: See service manual, 

chapter 

Replacing dancer arm springs 

 on page 272.

Exchanging the 

rewinder

 spring: See service manual, 

chapter 

Removing the dancer arm 

 on page 294.

Summary of Contents for ALS/XLS 204

Page 1: ...Edition 9 5 2019 Translation of original version SERVICE INSTALLATION MANUAL ALS XLS 20x 256 272 Labeler ...

Page 2: ......

Page 3: ...ions product profiles 22 Dimensions 22 Ambient conditions 23 Integration 23 Certificates Markings 23 Dimension diagrams 24 ALS 20x ALS 256 24 ALS 272 26 Performance data 28 Label rate 28 Dispensing speed over duration v t 30 Dispensing speed over length v x 31 Dispensed label length over duration x t 33 ALS XLS 256 Performance matrix 34 Installation and Deinstallation 36 Unpacking assembling and c...

Page 4: ...w 78 Notes on the description of functions 80 LABEL SETUP menu 80 MACHINE SETUP menu 82 INTERFACE PARA menu 90 Submenu EASYPLUGINTERPR 90 Submenu COM1 PORT 90 Submenu NETWORK PARAM 91 SIGNAL INTERFACE 93 Submenu PLC SIGNALS 93 Submenu APPLIC SIGNALS 94 Submenu AI BOARD SIGNAL 97 Submenu AI BOARD SIGNAL 98 Submenu ACTIVE INPUTS 98 SERVICE DIAGNOS menu 99 SERVICE DATA menu 100 Submenu MODULE FW VERS...

Page 5: ... 126 Loading Firmware 128 Firmware Version 128 Loading from USB stick 129 Download via data interface 130 Loading with the bootloader 132 Saving loading a configuration 134 Applications 134 Saving onto an external memory medium 134 Loading from an external memory medium 136 Automatic loading 137 Loading a configuration via the data interface 137 Interface commands 142 Command overview 142 Immediat...

Page 6: ...type Signals 199 Signal wave forms of applicator signals 200 Signals for PLC connection 209 Signal response Dispense End 210 Impact of the inhibit signal 211 Data interfaces 214 Overview connector positions 214 RS 232 214 Connection for external operator panel 214 USB device 215 USB host 215 Ethernet 215 Applicator Interface option 218 Important notes 218 Circuit diagrams for signal inputs 218 Cir...

Page 7: ...se plate 253 Opening the casing at machines held from the rear side 255 Overview Screws holding the casing rear wall 256 ALS XLS 256 272 Exchanging the fan 257 Unwind unit 259 Expanding mandrel 259 Brake 261 Dancer arm 263 Feed unit 275 Feed roller unit 275 Drive 281 Pressure roller 285 Rewind unit 288 Expanding mandrel ALS 2xx 288 Expanding Mandrel XLS 2xx 291 Dancer arm 294 Drive 300 Appendix 30...

Page 8: ...Service Manual ALS 20x 256 272 05 2019 8 Contents ...

Page 9: ...stments or repairs of the machine It is assumed that only knowledgeable and appropriately qualified persons are to perform installation adjustment or repairs Information about the required qualification see chapter Information and qualifications on page 15 Copyright notice All rights to this operating manual are assigned to NOVEXX Solutions Transmission reprinting or any other means of reproductio...

Page 10: ...h must absolutely be followed are particularly marked for special attention Illustrations When required text passages are accompanied by illustrations The illustrations normally show an ALS 2xx labeler as RH version XLS 2xx labellers or LH versions are only displayed if differences need to be highlighted The reference to an illustration is indicated by typesetting the illustration number in square...

Page 11: ... Tightening torques for the listed screw connections If special tools or other aids are needed for a task Tools List of the tools and aids that are required for the following activities Notes on installation and repair work General information Before performing any maintenance or repair work Block access to the working area of the machine to unauthorised persons Post a notification sign which call...

Page 12: ...them to enter the sewerage system or to seep into the ground Do not put old batteries removed parts and used cleaning agents in household waste Dispose of them in an eco friendly manner Packaging materials Only recyclable materials are used for packaging the machine Dispose of unwanted packaging material in an eco friendly manner Eco friendly disposal Sort the waste as much as possible e g separat...

Page 13: ... potential Lead the signal lines into the unit or switch cabinet from one side only The more lines that are laid in front and in back between the switch cabinet and the machine the larger the radiation surface of the radiated electromagnetic energy Lead the signal lines out of the machine in one bundle and from one location if possible and into the switch cabinet Twist together unshielded lines fr...

Page 14: ...EMC grounding via large metal surfaces Lay all lines as close as possible to metal parts even reserve cable Freely hanging lines act as transceiver antennas Ground all reserve cables and unused wires in the cables at least at one end Keep the cables as short as possible Cable resistance and signal distortion increase with the length of the cable ...

Page 15: ...tential dangers Knowledge 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 labeler offered by the manufac turer The service personnel must be acquainted with the functionality of the labeler The system integrator must be acquainted with the functi...

Page 16: ...ordance with the specifications in this manual Observe additional safety and warning notices attached to the labeler Observe and adhere to all relevant ordinances and rules in their applicable form1 WARNING Improper usage of the machine can lead to accidents material damage and loss of production When installing the labeler check for visible shipment damage Immediately inform Novexx Solutions of a...

Page 17: ...ith electrically live components can cause potentially lethal electrical shocks and burns After assembling check the printer according to the regulations relevant in your country WARNING Contact with energised components can result in life endangering currents through the body as well as burns The labeler is connected with the mains supply Only allow work on the electronics system to be done by au...

Page 18: ...ess condition of the electrical system Regularly check the electrical equipment Only connect the machine to other machines if these meet the requirements for a SELV cir cuit in accordance with EN 60950 Re tighten loose connections Immediately replace damaged lines After assembling check the printer according to the regulations relevant in your country WARNING Acute risk of injury and long term bod...

Page 19: ... m min max 30 m min max 50 m min max 25 m min max 70 m min Labelling halt precision at the peeling edge At fixed dispensing speed 2 0 5 mm At variable dispensing speed ALS XLS 272 all other machines 0 5 mm 1 mm Labelling halt precision on the product 3 At fixed dispensing speed 2 ALS XLS 272 1 mm Speed control Fixed setting or automatic speed adaption APSF via rotary encoder 4 Label material Conve...

Page 20: ...Labels inside or outside 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 dispensing edge V shape dispensing edge ALS XLS 204 19 mm 77 mm Sensor type Transmission sensor NPN PNP switchable System voltage ALS XLS 20x ALS XLS 256 ALS XLS 272 110 V AC at 60 Hz power frequency permissible tolerance 10 230 V AC at 50 Hz power frequency permissible tolerance 10 100 240 ...

Page 21: ... Control panel XLS 2xx Graphical display with background illumination 128 x 64 pixels 5 buttons Sensor interfaces for external sensors Label sensor Alternative label sensor Product sensor APSF sensor Rotary encoder Stock sensor plug in each case 4 pin M12 NPN 24 V PNP NPN 24 V PNP NPN 24 V single phase two phase PNP P P 24 V max 20 kHz PNP 24 V Internal sensor interfaces Material unwider Pressure ...

Page 22: ...onnection for Applicator Interface AI board special equipement Connector for additional motor driver not used Automatic halt if the label roll is spent or no gap was found the max admissible number of missing labels is reached Test functions Automatic diagnostics check when switched on Output of system data via data interface Status indicators Label counter Operating hours counter Storage location...

Page 23: ...ce when the equipment is operated in a commercial envi ronment 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 cause harmful interference in which case the user will be required to correct ...

Page 24: ...24 Technical Data DIMENSION DIAGRAMS ALS 20x ALS 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 ...

Page 25: ...Service Manual ALS XLS 20x 256 272 02 2019 02 25 Technical Data 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 26: ...Service Manual ALS XLS 20x 256 272 02 2019 02 26 Technical Data ALS 272 4 Abmaße ALS 272 Teil 1 3 0 101 332 225 225 3 2 0 2 0 5 266 492 504 31 57 22 41 352 88 74 118 154 ...

Page 27: ...Service Manual ALS XLS 20x 256 272 02 2019 02 27 Technical Data 5 Abmaße ALS 272 Teil 2 492 332 435 332 20 5 3 2 0 107 488 22 132 134 352 205 205 435 432 160 ...

Page 28: ...ding the gap and a dispensing speed of 20 m min a maximum of approx 750 labels per minute can be dispensed 6 Reading example of the maximum label rate To calculate the exact value refer to the Calculation sheet for performance diagrams on page 307 10 15 20 25 30 35 40 10 mm 25 mm 50 mm 100 mm 250 mm max ALS XLS 206 max ALS XLS 204 10 200 400 600 800 1000 1200 1400 1600 1800 Dispensing speed in m m...

Page 29: ...mber of labels per minute as a function of dispensing speed and label length 10 15 20 25 30 35 40 10 mm 25 mm 50 mm 100 mm 250 mm max ALS XLS 206 max ALS XLS 204 10 200 400 600 800 1000 1200 1400 1600 1800 Dispensing speed in m min Label rate in 1 min Label length including gap 0 500 1000 1500 2000 2500 0 10 20 30 40 50 60 70 Label rate in 1 min Dispensing speed in m min Label length including gap...

Page 30: ...peed C In this case the label is even shorter with the consequence 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 By the way The area below the graph equates to the label length What means that the areas below the graphs A and D must have the same sizes A v 40 m min l 50 mm B v 40 m min l 27 5 ...

Page 31: ...ng speed over dispensed label length 0 00 10 00 20 00 30 00 40 00 50 00 70 00 80 00 0 5 10 15 20 25 30 35ms m min C max ALS XLS 272 A B A v 70 m min l 15 mm B v 70 m min l 19 mm C v 70 m min l 25 mm Dispensing duration Dispensing speed 0 5 10 15 20 25 30 35 40 m min 45 0 10 20 30 40 50 mm max ALS XLS 206 max ALS XLS 204 A B C D A v 40 m min l 50 mm B v 40 m min l 27 5 mm C v 40 m min l 22 mm D v 3...

Page 32: ...ler 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 reached 12 ALS XLS 272 Diagrams with different settings for dispensing speed over dispensed label length 0 10 20 30 40 50 60 70 90 0 5 10 15 20 25 30 m min mm ma...

Page 33: ...h different settings for dispensed label lengths over dispensing duration 14 ALS XLS 272 Diagrams with different settings for dispensed label lengths over dispensing duration 0 5 0 5 10 15 20 25 30 35 40 10 15 20 25 30 mm ms A v 70 m min l 25 mm B v 70 m min l 19 mm C v 70 m min l 15 mm A B C Dispense duration Dispensed label length ...

Page 34: ...Example To reach a label stop accuracy of 0 5 mm with a dispensing 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 ALS 256 with L shape dispensing edge 155 mm wide Top labelling Label sensor Wenglor OPT242 P800 optical NPN Winding direction face out Sensor position to peel edge 19 mm Core diameter 3 Zoll APSF Other label...

Page 35: ... 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 0 5 1 9 N 50x125 0 5 0 5 0 5 ...

Page 36: ... M10 into the lo cation shown in 17A CAUTION To avoid damaging the machine during transport Only transport the machine in its orig inal packaging Keep the original packaging for a later transport WARNING Acute risk of injury and long term bodily injury from working with heavy loads Lift or carry the machine with a mini mum of 2 persons If possible use a crane or other lifting device CAUTION To avo...

Page 37: ...f the machine A joint 18B is used to attach the fix ing bolt to the support Advantage The machine can be inclined both side to side and forwards and back wards Side plate Requires a flange 18A to be mounted on the side wall of the machine Base plate Requires a flange 18C to be mounted on the base of the machine casing WARNING Risk of injury from a tipping over support stand When installing the mac...

Page 38: ...B in the holes in the fixing bolt 19A Screw the fixing bolt 20B onto the flange on the rear side of the machine with the screw provided 20C The two cylinder pins must locate into the holes 20A in the flange Mount the fixing bolt with its bevelled side pointing inwards towards the machine Tightening torque 350 Nm 19 Fixing bolt A for clamping the machine from the rear side The cylinder pins B preve...

Page 39: ...Set screws at the joint axis 23C 45 Nm WARNING Danger of injury by the machine falling to ground This danger exists if the machine is to be mounted so as enable sideways swivel ling i e if the pin in the joint is vertical If the machine is mounted incorrectly 22 it will fall to the ground as soon as the set screws clamping either the top or bottom half of the joint pin are loosened Always mount th...

Page 40: ...d washers A7622 Tool 8 mm hexagon socket driver Screw the flange plate 25C 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 25A Tightening torque set screw 25A 45 Nm Blind hole depth 13 mm 25 Attachment points B C A ...

Page 41: ... the dispensing edge holder can be adjusted in 15 increments Assembly Locate the pins 26C in diametrically opposite holes Choose either inner or outer circle of holes depend ent on angle required Fit the dispensing edge holder 26D onto the pins at the required angle Fix the dispensing edge holder in place with screw 26A Tightening torque 45 Nm CAUTION If the machine is operated with the dispens in...

Page 42: ... 2019 01 42 V shaped dispensing edge Tool 8 mm hexagon socket driver Mount V shaped dispensing edge as shown The angle of the V shaped dispensing edge cannot be changed It is mounted without fixing pins 27 V shaped dispensing edge in place ...

Page 43: ...oltage selection switch ALS XLS 20x Ensure that the ma chine is correctly adjusted to your local supply voltage ALS XLS 256 Only operate the ma chine using the system voltage indicated on the nameplate Only plug machine in to a correctly in stalled 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...

Page 44: ...power supply lead is un plugged Slide the switch 30A into its other position To do this insert a small screwdriver into the groove 30B and push the red insert horizontally until it stops in the opposite position for case shown in fig 30 to the left Switch position Permitted mains supply voltage 115 100 120 V AC 230 200 240 V AC Tab 2 Permitted mains supply voltages for the two positions of the vol...

Page 45: ... 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 32A ensure that the machine side power switch 31A is switched on position I the power switch at the splash guard 32B is switched off switch doesn t light 31 Power lead B plugged in ALS XLS 20x 32 M...

Page 46: ...racket and cable 1 5 m A101972 Sensor with bracket 33 A101971 Connection cable 1 5 m Connecting the photoelectric sensor Plug the photoelectric label sensor in to the connec tor shown 35A Pin assignment Pin Assignment 1 24 V 2 LED 3 Ground 4 Sensor signal Tab 3 Pin assignment for photoelectric label sensor connection 33 Novexx label sensor standard since 9 2011 34 Wenglor label sensor OPT242 P800 ...

Page 47: ...ction diagram 36 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 48: ...g move as many label gaps as possible at least 2 through the sensor fork The movement direction of the label gap is irrele vant that is the same label gap may be moved back and forth several times The label gaps have to be moved manually not by pressing the button If the label gaps were detected successfully the sta tus LEDs are flashing 2x 39 If the label gaps were not detected ideal the status L...

Page 49: ...etween NC NO Press the button 40A for at least 6 s until the status LEDs 40B 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 Mode Label LED Output Wenglor NPN Yes On Low No Off High Novexx NO Yes On High No Off Low Novexx NC Yes Off Low No On High Tab 4 Overview LED activity and output levels with or wit...

Page 50: ...rast 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 button until the LED 41A on the photoelectric sensor lights up Press the button and keep it pressed just be yond the point where the LED goes out Note the displayed value value 1 Place label material in the fork of the photoe...

Page 51: ... active sensor is done 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 42A ALS 256 42B Pin assignment 1 Changing light dark switching at the product sensor or the alternative label sensor on page 58 Connection accessories Article no Connector A8142 Connecting cable coupling plug A...

Page 52: ...ction diagram alternative label sensor Jumper descrip tion see Changing light dark switching at the product sensor or the alternative label sensor on page 58 24V 24V NPN Configuration NPN Signal PNP Signal PNP Configuration 2 2k 1k 1k 1 5k Signal Input GND Jumper default open 1 4 3 2 2 2k CPU Sensor connector ...

Page 53: ...GK TSSL 44 Sensor kit sensor sensor holder connection cable 45 A7775 for 160 mm wide dispensing edge holder A9995 for 230 mm wide dispensing edge holder Sensor holder A6059 for 160 mm wide dispensing edge holder A5574 for 230 mm wide dispensing edge holder N100456 Retrofit kit sensor with adapter plate matching the sensor holder connection cable 46 Application Replacement part for older no longer ...

Page 54: ...e holder Installation Tools Hexagon socket drivers 4 6 mm Turn out screw 48C and remove the dispensing edge 48E Remove the screws 48F from the bottom ends of the holding rods Take off the dispensing edge holder 48D Only with rotated dispensing edge holder Push the hold down roller 48G onto the holding rods and fix it with the thumb screw 48H Push the sensor holder 48A onto the holding rods and fix...

Page 55: ...ual ALS XLS 20x 256 272 02 2019 03 55 Installation and Deinstallation Installing the retrofit kit Screw the sensor to the sensorholder 49 Connect the cable 49 Attaching the retrofit kit to the sensor holder A B C ...

Page 56: ...bels be tween dispensing edge and capacitive sensor Fine adjustment of the stop position is done in the same way as with the standard label sensor Positioning the hold down roller 51A at machines with the dispensing edge holder rotated to the front Loosen the thumb screw at the holder of the hold down roller Push the hold down roller approx to the middle be tween the top crossbar 51B of the dispen...

Page 57: ...at least two la bels through the sensor fork Service and mode LEDs are flashing 2x The auto teach procedure has been concluded sucessfully The service LED lights green 4x The label was not detected optimally the best possible switching point will be set The service LED lights red Setting the Leuze sensor Read the service man ual chapter Setting the capacitive Leuze sen sor on page 306 53 Setting t...

Page 58: ...U2708 L1801 C1813 L405 C1520 L1806 R1516 R1501 R1136 R1507 R402 C1513 L1804 U2606 R1508 C1805 L1805 R1709 C1516 C1518 C1507 R1517 C1807 C1810 C1808 C1809 C1814 C1804 C1517 C1505 R2201 R1510 C1802 C1504 C1801 C1503 R1145 C1514 L1802 R2653 R2203 R2001 C1209 C2211 R2104 L2202 R2202 C2009 C2628 R2103 C2627 C2601 C1714 C1713 C1717 T1701 C1141 C411 R1001 U2703 R2735 R2722 R2736 R2737 U2704 R2721 R2728 R...

Page 59: ...or or the alternative label sensor on page 58 Connection Diagram 58 Connection diagram photoelectric product sensor 2 Alternatively the sensor A7112 can be connected to the optional applicator interface using cable N100136 Pin Assignment 1 24 V 2 24 V or ground or no connection 1 3 Ground 4 Sensor signal 56 Recommended photoelectric product sensor A Connection cable Article no A7127 B Data sensor ...

Page 60: ... s deviation roller 59C shim ring s and inner lock washer Remove reflector 60A and mounting bracket 60D from the sensor holder Remove the mounting block 60C 2 screws Move the sensor holder 60B behind the dancer arm with the upper end first and position it as illus trated 59 Push the mounting block onto the deviation roller axle and screw it to the sensor holder Push the shim ring which came with t...

Page 61: ...tional applicator interface see chapter Pin assign ment for machine status connection on page 224 Pin assignment Connection diagram 62 Connection diagram photoelectric RD sensor Pin Assignment 1 24 V 2 not used 3 Ground 4 Sensor signal Tab 7 Pin assignment for photoelectric OD sensor connection 61 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...

Page 62: ...ctor to the upper 63B or lower 63A 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 64C 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...

Page 63: ...spensed 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 a...

Page 64: ...1N 00500 Order no 121194 See www pepperl fuchs com Suitable measuring wheel 65A Type 9109 10 Order no 045565 Suitable mounting 65B Type 9213 Order no 045492 NOVEXX Solutions 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 24...

Page 65: ...nector de Connection diagram 69 Connection diagram rotary encoder CAUTION To avoid damage to the electronics Switch the machine off before con necting the rotary encoder Pin Common wire colours Function 1 Brown 24 V 2 White Impulse B 3 Blue Ground 4 Black Impluse A 66 Rotary encoder connector 67 Pin assignment rotary encoder connection 68 Recommended M12 connector ordering no A8142 for cable Ø 4 6...

Page 66: ...e two cabe inserts for two different diameter ranges 3 4 mm 5 6 mm Use the insert with the wider opening The inserts are split at one side Tool Open ended spanner SW 26 Procedure Remove the cover plate 72A from the cover box Turn out the cap 72B from the cover box Slightly spread the cable insert 72D to insert the cable Position the cable insert on the cable in a way that there is sufficient free ...

Page 67: ...he cover box and fix it with the nut 72G from inside Connect the cable see chapter above Reassemble the cover plate Mounting the external operator panel Tool Cross head screwdriver medium size Drill 2 holes according to the drawing beside 73 Arrows Open the operation panel housing 4 screws Mount the lower part of the housing using 2 M4 screws Close the operator panel housing 73 Hole distances for ...

Page 68: ...o be fed through the whole machine for each new material roll what reduces the downtimes for material change Tool 8 mm allen key Article numbers A107825 Splice table 000165 21 Screw M10x16 4 pieces required 000091 22 Washer 10 5 4 pieces required Mounting RH machine Screw the splice table 75A to the flange on top of the machine using the 4 screws 75B and washers Tightening torque 45 Nm 74 Splice t...

Page 69: ...to different signal interfaces using the optional available cables Article numbers Signal beacon with mounting angle without cable N100493 Connection cables 1 Required setting SIGNAL INTERFACE Interface mode PLC signals 2 Option The beacon can signal the following machine states Error red Warning yellow Ready Green Article number Connection to interface N100491 Standard 1 D sub 15 76A N100496 PLC ...

Page 70: ...ht adjustment of the dispensing edge Adjustment range 70 mm in steps of 0 2 mm 79 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 77A until the intend ed height is reached 79 Adjustment range of the adjustable dispensing edge holder 77 Adjustable dispensing edge holder A Adjustmen...

Page 71: ...Assembly Locate the pins 81C in diametrically opposite holes Choose either inner or outer circle of holes depend ent on angle required Fit the dispensing edge holder 81D onto the pins at the required angle Fix the dispensing edge holder in place with screw 81A Tightening torque 45 Nm Machine Article number ALS XLS 204 LH A107659 ALS XLS 204 RH A107658 ALS XLS 206 256 LH A107631 ALS XLS 206 256 RH ...

Page 72: ... pins 84C in diametrically opposite holes Choose either inner or outer circle of holes depend ent on angle required Fit the dispensing edge holder 84D onto the pins at the required angle Fix the dispensing edge holder in place with screw 84A Tightening torque 45 Nm 83 Install the roller A in the lower position B 84 Assembling the dispensing edge holder at an angle of 30 85 Material web path at the...

Page 73: ...ns 87C in diametrically opposite holes Choose either inner or outer circle of holes depend ent on angle required Fit the dispensing edge holder 87D onto the pins at the required angle Fix the dispensing edge holder in place with screw 87A Tightening torque 45 Nm 86 Install the roller A in the upper position B 87 Assembling the dispensing edge holder at an angle of 90 88 Material web path at the 90...

Page 74: ...ow label spring kit article number A8612 If the following creteria apply to the label material the Narrow label spring kit should be installed Less than 50 mm label width Weak or expandable stretchable backing paper 1 Only available as kit 89 Installation positions of the springs A Rewinder pressure spring B Unwinder tension spring C Unwinder pressure spring Spring Standard Narrow label spring kit...

Page 75: ...3 2019 03 75 Installation and Deinstallation Exchanging the unwinder springs See service manual chapter Replacing dancer arm springs on page 272 Exchanging the rewinder spring See service manual chapter Removing the dancer arm on page 294 ...

Page 76: ...nnect all cables at the machine Dismantling the machine Machine with installed applicator Remove the applicator For details read the applicator installation manual Let the machine be held by at least 2 persons while a 3rd person loosens the clamping at the support stand While doing so hold the machine at its housing Strip the machine from the support stand tube and lay it down WARNING Danger of in...

Page 77: ...applicator interface dispensing edge holder dispensing edge Dispose of the remaining machine parts separated by material groups in an environmentally ac ceptable manner Observe the national regulations Dispose of waste properly i e sorted according to the material groups of the parts to be dis posed of The aim should always be to achieve a maximum possible reutilisation of the basic materials comb...

Page 78: ... Store prod prof Startsen In Type 9 Interface FTP server Dispense speed Del prod profil Start disp mode Dispenser ID no FTP Password Slew speed Dispense counter Start error stop Spooler size WEB server Label pitch Disp Cnt Reset On inhibit enter WEB admin passw Lab stop offset Factory settings On inhibit leave COM1 PORT WEB supervisor p Start offset Custom defaults Turn on mode Baud rate WEB opera...

Page 79: ...y name End dispense mod Apply mode Sensor Test System revision Disp end delay Start mode PS registers 19 System date DISPLAY DATA End pulse width Dwell time 11 Memory card test Applicator int 16 Display Version Blow on time 12 Test functions Display serialNr APPLIC SIGNALS10 Restart delay Store diagnosis OPERATIONDATA Remote disp vers 17 Applicator type Position timeout 13 Gen Support Data Service...

Page 80: ...bel material after switching the device on after changing the label material Settings Manual Autom forward Manual The operator has to initialize the material always manually by pressing the feed button several times Autom forward The material initialization is always done automatically if necessary Dispense speed function Speed at which the label is dispensed Adjustment range ALS XLS 204 1 0 40 0 ...

Page 81: ...els start Each start signal causes printing of x labels x 2 20 x 3 The distance of all following labels after the 2nd label matches the value set in LABEL SE TUP Label 2 offset The Multi label mode function works only if a standard signal input M12 or D Sub 15 is used it doesn t work if an Applicator Interface is applied as signal input Label 2 offset function Only appears if LABEL SETUP Multi lab...

Page 82: ... On 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 Off The labeler counts up i e each label dispensed increases the counter reading Label stop quan function After this amount of dispensed labels the dispenser stops Function only appears if LABEL SETUP Stop count mode On Setting range 0 99999 default 0 MA...

Page 83: ...ults function Settings Apply current Delete Apply current Stores the current function settings as default values The stored settings are reinstalled by calling MACHINE SETUP Factory settings Custom defaults Delete Deletes the stored customer specific settings Delete is only visible if settings have already been stored Store Parameters function Saves the settings of the functions to a file on the C...

Page 84: ...of rotary encoder used Settings Single Phase 2 Phases normal 2 Phases invert Appears only if MACHINE SETUP Speed Adaption On See chapter Entering the rotary encoder type on page 106 Encoder Resol function Resolution of the rotary encoder used Adjustment range 0 0 9999 pulses turn default 500 Appears only if MACHINE SETUP Speed Adaption On See chapter Entering the rotary encoder resolution on page ...

Page 85: ... slave machine both have a separate start sensor The start offset has to be set at each machine separately LABEL SETUP Start offset Tandem synchron function To choose the interface via which tandem operation is synchronised Settings None Serial Com1 UDP Tandem Port None Serial Com1 UDP Tandem Port No tandem operation together with Tandem Operation Off Serial Com1 Tandem synchronisation over Com1 I...

Page 86: ... production mode Labels are dispensed for as long as the signal at the sensor signal input remains at the value high Pulse fall ris Dispensing a label is triggered both by a change from low to high and by a change from high to low at the sensor signal input Start error stop function Refers to the standard procuct start input M12 connector see chap Photoelectric product sen sor on page 59 Determine...

Page 87: ...ing cycle is finished On inhibit leave function On leaving inhibit means after the inhibit signal stopped The function only affects the inhibit input at the standard signal interface in PLC mode The in hibit input at the optional applicator interface is not affected The function determines how products are handled which already had passed the start sensor as the inhibit signal stopped The start si...

Page 88: ...ntered Off Password check deactivated Materialend err function Refers to the internal OD control Settings Off 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 button Defines the diameter threshold for the material roll If the calculated material roll diameter is below the threshold value the following status m...

Page 89: ...sage appears Setting range 50 500 mm Default setting 202 mm Ext OD sensor function Refers to the external OD light barrier option Settings Off Warning Error Off OD sensor is disabled Warning OD sensor is enabled If the outer roll diameter is less than the critical value the signal output Warning is activated Error OD sensor is enabled If the outer roll diameter is less than the critical value the ...

Page 90: ...ment range 0 31 Sets the identification number of the labeler The labeler can then be called with the interface command An n labeler ID Setting up ID numbers is particularly sensible for data transfer via RS422 485 interface if more than one labeler is connected via a data link Each of the labe lers connected then only processes the data addressed to it using the An command Spooler size function T...

Page 91: ...sation by hardware XON XOFF Data synchronisation by software None Handshake lines are not monitored Frame error function Settings Display Ignore Display An error message is shown if frame errors occur during serial transfer Ignore Frame errors are ignored no error message is displayed Submenu NETWORK PARAM General rules for entering addresses To change to the next previous alphanumeric character P...

Page 92: ...ith full duplex operation 100M Half duplex Transfer rate 100 MBit s with half duplex operation 100M full duplex Transfer rate 100 MBit s with full duplex operation MAC Address function Displays the MAC address of the CPU Board This address cannot be altered via the menu DHCP host name function Host name of the labeler default Device Name the last 3 characters of the MAC address Permitted character...

Page 93: ...t operator Access rights to functions are equivalent to those in production mode see MACHINE SETUP Ac cess authoriz SIGNAL INTERFACE Interface mode function Sets the operation mode of the standard signal interface Settings PLC signals Applic signals PLC signals The signal interface provides PLC signals Applic signals The signal interface provides signals for applicator control Submenu PLC SIGNALS ...

Page 94: ... on time the applicator moves back into home position PEP II Sensor The cylinder movement is limited by a touchdown sensor which signals the contact to the product and triggers the backwards movement ASA Vintage applicator Same function as LA BO Reverse PEP Combined tamp on blow on applicator The applicator moves to its end position and waits for the start signal The start signal triggers the blow...

Page 95: ...label After start sig The start signal triggers the application of a label that has already been dis pensed The next label is then dispensed immediately after application Dwell time function Appears only if SIGNAL INTERFACE APPLIC SIGNALS Applicator type PEP PEP Blow on Reverse PEP BTS or LA TO Timed Determines the length of time for which the applicator is extended Is required for applicators tha...

Page 96: ...0 ms Apply comp time function Compensation time for the applicator stroke time required for operation with variable conveyor speed Setting range 0 99999 ms Most applicators have a constant stroke time If the labeler is driven with variable speed this leads to different label positions on the product With a slow conveyor speed the touch down comes too early with a high conveyor speed it is too late...

Page 97: ...e Pulse rising Level high activ Pulse fall ris Pulse falling The dispensing of a label is triggered by a high low change of the start signal The dispensing occurs only after the set delay time Level low active Labels are being dispensed as long as the start signal is held low Pulse rising The dispensing of a label is triggered by a low high change of the start signal The dispensing occurs only aft...

Page 98: ...t signals at different interfaces This can e g be the case with some signals at standard signal interface and optional applicator interface AI Start signal function Settings Default input Opt appl interf Default input Activates the standard start signal input M12 connector Opt appl interf Activates the start signal input at the optional applicator interface Setting ap pears only with the optional ...

Page 99: ...nly for authorised trained service personnel Memory card test function Test function for compact flash cards Pressing the Online button starts a test routine for the compact flash card memory After a suc cessful test the following is displayed If the compact flash card is faulty or not in place an appropriate error message is displayed Test functions function Starts motor durability test Both moto...

Page 100: ... 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 the flash memory contains more than one data block Press the cut button several times until the ...

Page 101: ...perations function Shows the total number of services that have been carried out Increment the counter by using SERVICE DIAGNOS Service Maximum value 4 Bn Tot mat length function Displays the total material length that has been fed i e the mileage of the drive roller Maximum value 4 Bn metres Dispensing cycl function Counter for the number of labels dispensed Operation time function Displays the t...

Page 102: ...ction Displays the MAC address an address for the board which is programmed by the manufacturer and cannot be changed Serial number function Displays the serial number which is programmed in by the board manufacturer Production date function Displays the date of manufacture of the CPU board PCB part number function Displays the part number of the board without components Board part numb function D...

Page 103: ...e operator panel Submenu PERIPHERAL DATA Applicator int function Function only appears when there is an applicator interface installed Shows the PCI model of the applicator interface Submenu MEMORY DATA RAM memory size function Shows the size of the available RAM Flash mem size function Shows the size of the available flash memory Custom defaults function Shows if custom default settings are store...

Page 104: ...ns ing speed to the speed of the conveyor belt The conveyor belt and the label feed operate in perfect synchronisation thanks to the automatic speed adjustment 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 automatically The speed of the conveyor belt is picked up by a rotary encoder 90A and ...

Page 105: ...belt takes the part of the measuring wheel Accord ingly the diameter of the driving gear 92D must be entered into function MACHINE SETUP Encoder Diameter 92 Mounting the rotary encoder onto the driving axle of the conveyor belt D Diameter of the driving gear Rotary encoder at the motor axle The rotary encoder is mounted onto the motor axle The rotation speed of the motor is normally transmitted vi...

Page 106: ...94B The diameter of the measuring wheel therefore influences the rotational speed of the rotary encoder 94 A Measuring wheel B Rotary encoder Call the function MACHINE SETUP Encoder Diameter Enter the diameter of the measuring wheel to be used Adjustment range 0 0 200 0 mm Entering the rotary encoder type Depending on the features of rotary encoder and labeler there are different ways to count the...

Page 107: ... labeler the labeler calculates nonsense speed values The following measures correct this problem Operating the rotary encoder in opposite direction e g by mounting it on the opposite side of the conveyor or Changing the cables that is exchanging A and B or Connecting the inverse signal B instead of B or Configuring the inversion of signal B at the labeler Set function MACHINE SETUP Encoder Type t...

Page 108: ... the input fields 95A In the rightmost column appear warning notes if questionable values are entered 95B Read the calculation results 95D In the rightmost column appear warning notes if questionable values are entered 95E Inputs 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 w...

Page 109: ...page 105 v max speed Maximum dispensing speed which should be reached by the labeler Limits flimit max frequency The maximum admissible signal input frequency is 20 kHz This is dependent on the galvanic separation and a digital 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 r...

Page 110: ...Service Manual ALS XLS 20x 256 272 02 2019 02 110 ...

Page 111: ...deration As a rule unlabelled products can be prevented At the idle machine the operator has the option to reload with new label material or to eliminate minor malfunctions The first machine in the production line is designated as the master device the second is designat ed as the slave device Normally the master device is activated first Master operating modes The master machine can be set to mas...

Page 112: ...able 97 Both machines must be set for the use of the rotary encoder The product sensor is connected to both machines using the Y cable 97 Alternatively can a separate product sensor be connected to each master and slave to increse dispense accuracy Prerequisites for both machines are Electronics Gen 2 Firmware Version 2 50 or higher Tandem interface cable for synchronisation over Com1 Article numb...

Page 113: ...rt 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 white 3 blue 4 black 1 brown 2 white 3 blue 4 black 24V Signal B GND Signal A Plug to machine male Plug to machine male Coupling to sensor female Binder Series 713 ...

Page 114: ...cable a standard null modem cable can be used Synchronisation over Ethernet interface peer to peer that is direct connection without network Connect the crossover network cabel to the ethernet interface C on both machines 99 Connections for the tandem interface cable A B If both machines are connected to a network standard 1 1 network cables are required for connection brown yellow metal cover or ...

Page 115: ...e INTERFACE PARA EA SYPLUGINTERPR Interface not Serial Com1 and not Auto negotiation During tandem operation Com1 is used for communication between master and slave machine Therefore the interface function may not be set to Auto negotia tion 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 ...

Page 116: ...resses 127 xxx xxx xxx must not be used 101 Distance A between the dispensing edges of the two labelers Settings on Menu Submenu Function Setting Master and Slave INTERFACE PARA EASY PLUGINTERPR 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 101A between the dis pensing edges of ...

Page 117: ...after switching on the following warning shows up If communication succeeds within 5 minutes after the first appearance of the warning the warn ing will disappear If no communication was established within 5 minutes after appearance of the warning the fol lowing error messages will appear Master Slave Display on master Master mode Flipflop master mode The machine is ready for operation and begins ...

Page 118: ...rror occurs the slave is automati cally activated The master can be refitted while the slave takes over dispensing At the master Press the button to confirm the error message Refill master Press the button to reactivate the master Afterwards the master starts and the slave stops CAUTION Machine stoppage in case of material end at the slave while the master is stopped Ensure sufficient material sup...

Page 119: ...ed xxx Online Slave Labels xxx Activate master Press the button Master is labelling Online Master Labels xxx Online Slave Dispenser locked Status Master Slave Master is labelling Online FF Master Labels xxx Online Slave Dispenser locked Material end at master slave starts labelling Status num 5002 Material end Online Slave Labels xxx Acknowledge error Press the button Replenish material Slave is l...

Page 120: ...to the master as soon as a material warning occurs what means that a preset roll diameter is reached see MACHINE SETUP Materialend warn resp MACHINE SETUP Ext OD sensor Stopping continuing labelling To stop labelling Press the button Display 2 Or Online FF Master or Online Slave This has no effect on the second machine To continue labelling Press the button Online Master 2 Stopped xxx ...

Page 121: ...oses or safety guards System requirements The following applicators are available for labelers of the types ALS XLS 20x and ALS XLS 256 LA TO tamp on applicator 103A LA BO blow on applicator 103B The applicators are controlled via one of the following interfaces Standard signal interface see Signals for applicator connection on page 197 optional applicator interface see Applicator Interface option...

Page 122: ...nel display Gives access to all the functions of the real operator panel E Starts the FTP server in a new browser window See chapter FTP server on page 126 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...

Page 123: ...nstalled on the host e g Firefox Internet Explorer Chrome Starting the web server Note down the IP address of the labeler This is shown under INTERFACE PARA NETWORK PARAM IP address Start internet browser Enter the following in the address bar http IP address without initial zeroes Example IP address 144 093 029 031 Enter http 144 93 29 31 Logging in to the web server Click on the Login link 104B ...

Page 124: ... changed on the labeler via the operator panel However if any of these functions is changed via the web server the reset does not occur automatically The changes only come into effect after the next time the labeler is reset In these cases the Reset button 106A appears after the setting has been changed 106 Information A Changes made to the function setting do not come into effect until after a re...

Page 125: ...l The buttons 107A 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 chapter Loading from USB stick on page 129 Equivalent to the combination C Reset button Triggers a res...

Page 126: ...network administrator or by a DHCP serv er INTERFACE PARA NETWORK PARAM FTP server must be set to On FTP client is installed on the host computer e g WS FTP Windows Explorer Internet Explorer Midnight Commander The FTP connection is not blocked by a firewall Establishing a FTP connection Note down the IP address of the labeler This is shown under INTERFACE PARA NETWORK PARAM IP address Start the F...

Page 127: ...nctions for storing setup or diagnosis data on a memory medium was already pro cessed the following subfolders can be found here 1 1 Depending on the applied memory medium appears SD CF or USB Subfolder Comment Formats Location for setup files see MACHINE SETUP Store Parameters Location for firmware files to be uploaded in standalone mode Logfiles Location for diagnosis files see SERVICE DIAGNOS S...

Page 128: ...com CAUTION Executing or applying the update procedure incorrectly can set the machine into a crit ical condition which can only be rectified by trained technicians Firmware should therefore only be updated by experienced operators or service technicians Update firmware only if a a newly provided function is badly needed or b the ma chine doesn t work properly Never switch off the machine during a...

Page 129: ...MATS directory or there is no USB stick plugged in the following message appears Downloading Firmware Files with the extension S3B are understood to be firmware Selecting a firmware file starts the file This constitutes a considerable intervention in the system and is therefore queried first before being carried out After the question Download firmware Yes No the system waits for confirma tion fro...

Page 130: ...via the interface which has been activated through the menu INTERFACE PARA EASYPLUGINTERPR Interface Com1 USB or Ethernet Host computer operating system Windows XP Firmware file is saved on the host computer Current firmware can be downloaded from the following website www novexx com Service Firmware Serial interface On the host computer Open a command prompt window Enter Replace ALS BF2_V2 51 s3b...

Page 131: ...hen clicking PROPERTIES SHARING Windows 7 START DEVICES AND PRINTERS Right click on the relevant printer then on PRINTER PROPERTIES then on the SHARING tab The printer must be setup especially for this purpose Find an how to instruction in chap ter Installing a Generic printer on a Windows 7 host PC for the purpose of firmware upload on page 302 Some tips about transfer via a USB or Ethernet inter...

Page 132: ...t Download Pressing the button starts data receiving via the serial interface Data must match the following requirements Transmission parameters 115200 n 8 1 xon xoff Firmware file in format s3b e g ALS BF2_V2 51 s3b Display texts appearing during the transmission USB load Pressing the button starts loading firmware from USB stick Data must match the following requirements Firmware file must be na...

Page 133: ...Service Manual ALS XLS 20x 256 272 02 2019 02 133 Enhanced Functions Version Pressing the button displays the bootloader version revision and build no ...

Page 134: ...edium as a text file setup file see description that follows For details about applying external memory media refer to the External memory media manual Saving onto an external memory medium Switch the labeler off Connect a memory medium to the USB connector Switch the labeler on Call MACHINE SETUP Store Parameters This function only appears in the menu if there is a memory card in the labeler s ca...

Page 135: ...x 256 272 02 2019 01 135 Enhanced Functions File name and directory can be changed using buttons on labeler operator panel If a file with the name entered already exists this will be overwritten without asking for confirma tion ...

Page 136: ...configuration file was selected the configuration is loaded For a firmware file the firmware starts loading If there are no suitable files in the FORMATS directory or no memory medium is connected the following message appears Loading procedure Select file as described above Press the button Display Top line selected file name The loading can take a couple of seconds To visualize the progress the ...

Page 137: ...RA EASYPLUGINTERPR Schnittstelle Com1 USB or Ethernet Host computer operating system Windows XP Windows 7 or Windows 10 Serial interface On the host computer Open a command prompt window Enter the command copy setupall for com1 112 replace setupall for with your filename Press the Enter key 112 Command prompt window showing the command to transfer the file setupall for to the interface Com1 USB Et...

Page 138: ...PC2071 0 G EasyPlug errors Tolerant handl PC2068 5 G Foil stretching Feedback 5 mm PC2043 0 G Start print mode Pulse falling 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 0 0var PC6040 1 G Rewinder Operat On PC6046 1 64 G Rewinder gear Reduction 1 1 64 PC6018 0 G Tandem Operation Off PC6047 0 G Ta...

Page 139: ...0 0 G Time zone 0 00 G G Signal Interface Parameter Menu G PC6033 0 G Interface mode PLC signals G G PLC Signals Parameter Menu G PC3211 0 G End dispense mod Mode0 inactive PC3213 100 G Disp end delay 100 ms PC3214 0 G End pulse width 0 ms G G Applicator Signals Parameter Menu G PC6101 0 G Applicator type LTP LTPV PC6112 0 G Status outputs Off PC6102 0 G Apply mode After start sig PC6115 0 G Touch...

Page 140: ... 00 00 00 00 00 50 5A 2D 3C 03 00 00 00 G readonly ID 30210 G PS Reg 0x0A0 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 G readonly ID 30211 G PS Reg 0x0B0 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 G readonly ID 30212 G PS Reg 0x0C0 10 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 G readonly ID 30213 G PS Reg 0x0D0 00 4B 50 25 32 03 00 00 00 00 FF 37 00 00 00 00 G readonly ID 30214 G PS Reg...

Page 141: ...75 60 2074 80 2076 202 6022 0 6028 0 6044 0 6045 0 6023 0 6024 15500 6025 15500 6029 15500 6030 15500 1101 5 1102 0 1104 64 2072 0 2021 0 1201 8 1202 8 1203 2 1204 1 1205 0 1206 0 1207 1 1501 0 1505 9100 1506 0 1513 ALS_204_LH_000000 1507 1 1508 novexx 1509 1 1510 5 1511 admin 1512 supervisor 1532 operator 1529 0 1530 2105212662 1531 3600 1533 0 0 6033 0 3211 0 3213 100 3214 0 6101 0 6112 0 6102 0...

Page 142: ...readout of menu function set tings via the interface that is set up for use 4 Function ID identification num ber 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 profile n name of the product profile Function ID identification num ber of menu function PC Function ID Value G Adjus...

Page 143: ...r These can then be trans ferred to another device see PC command x Meaning A Self quitting U Requires user quit N Can not be quitted requires reset F Quit method is not defined 0 Status message was already quit Tab 23 Possible quit methods of the returned status messages n Effect 1 Values for machine specific settings e g sensor adjustment values are commented out 4F by adding a to the front of e...

Page 144: ...ersion V1 01 G Serial Number A637105450041 G MAC Address 000a 44 04 00 1d G G LABEL SETUP G PC6000 10 0 G Dispense speed 10 0 m min G f 0 0 40 0 0 1 PC6001 10 0 G Slew speed 10 0 m min G f 0 0 40 0 0 1 PC6002 100 0 G Label pitch 100 0 mm G f 5 0 600 0 0 1 G G MACHINE SETUP G PC5050 1 G Dispenser type ALS 204 RH G d G 0 ALS 204 LH G 1 ALS 204 RH G 2 ALS 206 LH G 3 ALS 206 RH A B C D E F Function ty...

Page 145: ... one bit 8 is set Function ID Value Function Function in menu 2005 n 0 Maxint 1 Label counter MACHINE SETUP Dispense counter 2065 n 0 16 Loads product profile no n A valid 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 SI GNALS Disp end delay 6000 f 0 0 MAX...

Page 146: ...onal Causes that the assigned value is only stored in the RAM of the machine not in the Flash memory for details read info text below Separator n Name of the product profile Bit Meaning 0 New start signal during the dispensing operation 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 d...

Page 147: ... 0 6101 0 6112 0 6102 0 6113 1 6106 1 6107 0 6108 0 6109 2000 6111 0 3112 1 3101 6 3102 0 3110 2 3116 1 3106 1 31 07 1 3108 0 3115 80 3109 2000 3111 0 3230 0 3231 0 3232 0 5111 0 5112 0 5127 1 5124 0 5128 1872945986 5404 0 5400 0 5401 0 5402 0 5408 0 5403 0 5406 0 5407 0 G Use of N Stating N provokes that the parameter value s of a product profile are not immediately written into the Flash memory ...

Page 148: ... the concerned machine at first It thus emerges which parameters are relevant for the respective machine The reading out can be done one of the following ways Via the immediate command PGn see chapter The PGn command on page 1 Saving a setup file on a memory card see chapter Saving loading a configuration on page 132 To activate the setting the machine must be reset after sending the PC command Th...

Page 149: ...factory settings with custom defaults if available equates to MACHINE SETUP Factory settings Custom defaults if not use factory defaults equates to MACHINE SE TUP Factory settings Factory defaults Value Function Tab 30 Handover values for the command PC999999 for special purposes ...

Page 150: ...ONS with the single function Clear Params shows up Press the button Press the button to change to yes Press the button All settings in the functions menu are deleted including 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 displayed After this display press the following buttons in succession 3...

Page 151: ...ar All settings in the functions menu are deleted including 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 displayed After this display press the following buttons in succession 3x Set the machine type under MACHINE SETUP Dispenser type Switch the machine off and on again after waiting at least...

Page 152: ...ps 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 the following ways Reading out via serial interface Storing on an external memory medium as logfile In the Flash memory a certain area is reserved for diagnose dumps which provides enough space for 3 4 dumps If this area is already filled the olde...

Page 153: ...the new connection 113A Click OK The window Connect opens 114 Set the transfer parameters Select the serial 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 115 Hyperterminal main window A ...

Page 154: ...his starts data being read out of the printing device and being displayed in the Hyperterminal main window 116 At the same time the data are saved in the record file To stop the transmission click Cancel in the menu 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 circumstances in which the e...

Page 155: ...ATA 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 pressing 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 keyboard ...

Page 156: ...N START LABEL OD APSF A7301 A7301 A6794 A8132 A6627 A7679 A7777 A7778 A6803 A6379 A7389 A7060 A7068 A6727 A6727 A6727 A6727 A6727 A5001 A6805 A4455 A6571 A7620 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 ...

Page 157: ...L 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 158: ... 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 159: ...3 Rewinder dancer arm sensors Material end sensor Operator panel Rewinder motor Transport motor Transformer Motor driver board CPU board Applicator interface accessory Power supply A8132 A7301 A7301 A6794 A7060 A7679 A7777 A7778 A6627 ALS 20x N101590 XLS 20x A6801 A7620 A6804 A103782 A7389 A6803 A6802 A6571 A4455 A5001 A6805 75V 17V 5V 24V 24V 110V 230V ...

Page 160: ...l Rewinder dancer sensors Rewinder motor Transport motor Motor driver board CPU board Fan Power supply ALPS 600 CAP PLC OUT PLC IN START LABEL OD APSF A8132 A6804 A7950 A6801 A7620 A6627 ALS 2xx A7679 A7777 A7778 A7060 A7301 ALS XLS 256 A7128 ALS XLS 272 A8463 A6803 A8464 A6802 5V 24V A7389 A103782 A8734 24V A8171 A8734 75V 17V A7068 A6727 A6727 A6727 A6727 A6727 N101800 XLS 2xx ...

Page 161: ...ALS 272 A8132 A7950 A6804 A6801 A7620 A7777 A7778 A7679 A6627 ALS 2xx A6727 A6727 A6727 A6727 A6727 A7068 A7060 A8436 A6802 A8464 A6803 A8171 A6805 A8734 A5001 A4455 A103782 A7389 N101800 XLS 2xx Rewinder dancer arm sensors Transport motor Rewinder motor Material end sensor Operator panel CPU board Motor driver board Fan Applicator interface board accessory Power supply ALPS 600 CAP PLC OUT PLC IN...

Page 162: ...sition 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 galvanicall...

Page 163: ...LS 20x rear wall of casing removed A Toroidal transformer B CPU board fig shows Gen 1 board C Operator panel D Photoelectric sensors to determine position of rewind 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 ...

Page 164: ... ALS 256 rear wall of casing removed A CPU board fig shows Gen 1 board B Operator panel C Photoelectric sensors to determine position of rewind 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 165: ...ctronic components of ALS 272 rear wall of casing removed A CPU board B Stepper motor for the rewind unit C Photoelectric sensors to determine position of rewind unit dancer arm D Motor driver E Connections for sensors PLC inputs outputs F Stepper motor for the label feed G Power supply unit A B C D E F G ...

Page 166: ...56 272 02 2019 03 166 Electronics Description CIRCUIT BOARDS CPU board Gen 1 Connections and configuration 117 Connections on the CPU board Gen 1 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 ...

Page 167: ...ltage connection for applicator interface 24 V I CN 501 Power supply unit connection Power supply for the board with 5 V and 24 V J CN 702 Connection to applicator interface K JP 601 Jumper micromonitor Diagnostic software for factory internal use Preset open L JP 602 Jumper with no function M CN 802 Connection for additional motor driver optional N CN 808 Sensor connection for internal roll diame...

Page 168: ...face device AD CN 103 USB interface for optional internal use AE D 506 Green display to indicate 5 V supply AF CN 901 PLC signal interface For activating simple applicators AG D 507 Yellow display to indicate 24 V supply AH CN 907 Connection for the M12 socket for signal inputs AI CN 908 Connection for the M12 socket for signal outputs Yellow Continuously lit Labeler is connected with the network ...

Page 169: ... 02 2019 03 169 Electronics Description Preset jumper positions If a defective CPU board has to be replaced Set or remove the jumpers on the new board as shown 118 CPU board Gen 1 These jumpers on the board must be connected or removed ...

Page 170: ...Service Manual ALS XLS 20x 256 272 02 2019 03 170 Electronics Description Layout diagram 119 Layout diagram for the CPU board Gen 1 ...

Page 171: ...3V 2 5V 1 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 quadratu...

Page 172: ...0x 256 272 02 2019 03 172 Electronics Description CPU board Gen 2 Connections 121 Connections and jumpers on CPU board Gen 2 A103782 26 24 25 2 16 3 14 9 8 7 6 4 12 11 10 5 13 18 27 19 17 28 20 1 21 15 23 22 30 31 29 C D E A B ...

Page 173: ...tional 13 CN2001 RFID RFID read write control unit optional 14 CN2101 I2C_SENSE ALS 256 ALPS 600 power supply I2 C bus 15 CN2102 APPLICATOR Applicator interface 16 CN2401 SMB2 Additional motor driver board optional 17 CN2402 SMB1 Motor driver board 18 CN2501 DANCER4 Dancer arm sensor 4 optional 19 CN2502 DANCER3 Dancer arm sensor 3 rewinder 20 CN2503 DANCER2 Dancer arm sensor 2 optional 21 CN2504 ...

Page 174: ...ensor either to 24 V or to ground See chapter Changing light dark switching at the product sensor or the alternative label sensor on page 58 D JP2602 If the jumper is set it connects pin 2 of the alternative label sensor either to 24 V or to ground See chapter Changing light dark switching at the product sensor or the alternative label sensor on page 58 E none Must always be set Tab 42 Jumpers on ...

Page 175: ... 02 2019 03 175 Electronics Description Preset jumper positions If a defective CPU board has to be replaced Set or remove the jumpers on the new board as shown 122 CPU board Gen 2 These jumpers on the board must be connected or removed ...

Page 176: ... R405 C1005 R2651 C2412 RP2707 U2705 U2706 C2712 R2723 R2731 R2732 U2709 U2707 RP2701 C2708 C2419 CN2402 R407 R2212 R2510 R2501 C2408 C2405 C2409 C2407 R2107 C2602 L2101 C2102 R2101 C2105 F2102 R2213 RP2406 RP2301 C2210 R2205 C2404 RP2401 RP2403 RP2404 C2403 C2402 RP2402 U2401 RP2407 R2504 R2502 R2503 C2522 CN2502 CN2504 R2508 C2521 R2507 R2506 R2511 CN2503 R2505 C2520 R2509 C2505 C2501 C2513 C251...

Page 177: ...inuously lit High transfer rate 100Mbit s C H401 Yellow indicator for 24 V supply voltage D H402 Green indicator for 5 V supply voltage E H601 Indicator for 3 3 V supply voltage F H2301 Operation indicator for CPLD U2301 G H2401 Indicator for 24 V supply voltage at sensor connectors H H2701 Indicates that the output driver U2701 switched to overcurrent and or overheat protection I H2702 Indicator ...

Page 178: ...trial sensor NPN or PNP selectable NPN PNP config gap signal Optical Label Sensor 24V industrial sensor LED current control NPN output LED current current feedback gap signal OD Sensor 24V industrial sensor PNP signal outer diameter APSF Sensor 24V industrial sensor 2 phase push pull signals signal phase A signal phase B intelligent BLDC motor driver CAN bus 3 x Light Barrier Sensor Dancer Arm 3 q...

Page 179: ... rewinder motor G D 202 Status LED red feed motor 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 part when delivered from factory Littelfuse Series 215 B A C D E F G...

Page 180: ...Service Manual ALS XLS 20x 256 272 02 2019 03 180 Electronics Description Layout diagram 127 Layout diagram for motor driver board ...

Page 181: ...rator panel assy A6627 applied to ALS machines 129 Operator panel assy N101590 applied to XLS machines A CN 2 Programming adapter connection Only for factory internal use B CN 4 Connection for cable to button C Connecting cable to button D CN 5 Connection for cable to button E CN 1 CPU board connection B D E A C E ...

Page 182: ...Service Manual ALS XLS 20x 256 272 02 2019 03 182 Electronics Description Layout diagram 130 Layout diagram for operator panel ALS ...

Page 183: ...RQWUROOHU 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...

Page 184: ...y 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 on page 128 Updating AI boards is earliest possible with change index 02 Firmware CPU Firmware AI Electronics 1 01 1 17 Gen 1 1 02 1 10 1 18 1 33 1 23 Gen 1 1 40 1 37 1 51 1 38 1 52 1 41 2 51 1 38 Gen 2 2 52 1 41 2 6...

Page 185: ...ignal 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 H JP 101 104 JP 202 Jumpers for factory internal use A B C H I J D K O L a G E F M N ...

Page 186: ... 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 187: ...Service Manual ALS XLS 20x 256 272 02 2019 03 187 Electronics Description Layout diagram 134 Layout diagram for Applicator Interface PCB A3417 03 ...

Page 188: ...4hd Internal 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 Senso...

Page 189: ...agon socket driver 2 5 mm Open the casing see Ch Opening the casing page 252 Remove two screws B at the slot cover Remove slot cover 136 Slot cover A with mounting screws B Remove two screws A at the board rack Carefully pull out the board rack until the connec tions at the rear end of the CPU board are accessible 137 Board rack with mounting screws A LH version pictured Connect both cables to the...

Page 190: ... sockets A at the board rack 138 Plug the Applicator Interface onto the spread sockets A on the board rack Reinstall the board rack While doing so pay attention that the noses at the rear end of the board rack fit into the holes at the housing rear wall not to wedge any cable between board rack and housing Close the casing A ...

Page 191: ...PU board B Connection for transformer C Mains power switch D Socket for power cable E Fuse holder for fuse F1 T5AH 250 V F Fuse holder for fuse F2 T5AH 250 V See chapter Fuses on page 192 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 Input 10 Power Fail Output Pin Description 1 Neutral lead 2 110 V AC 3 230 V AC A C D E F G B 1 3...

Page 192: ... The fuse holder springs out Remove the fuse from the fuse holder Replace defective blown fuses Fuse type required T5AH 250 V Original part when delivered from factory Bel Fuse Type 5HT Time lag fuse high braking capacity Put the fuse holder back into place and turn clockwise pressing in gently until the slot is vertical Active fuse Mains voltage Position of switch F1 230 V 230 F2 110 V 115 Tab 45...

Page 193: ...s 140 Transformer windings Power supply ALS XLS 256 272 Connections and configuration 46 Connections on the A8171 power supply unit 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 A A C D E B ...

Page 194: ...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 5 GND Pin Description 1 2 24 V 3 4 24 V Grou...

Page 195: ...d as interface for applicator signals or for PLC signals The selection of the interface type is done via the function menu PLC signals SIGNAL INTERFACE Interface mode PLC signals Applicator signals SIGNAL INTERFACE Interface mode Applic signals Recommended connector Novexx article no A8144 male A8145 fem Manufacturer Franz Binder GmbH Order no 713 1 99 1487 812 08 See www binder connector de 141 P...

Page 196: ...of the optional M12 sockets A Outputs B Inputs Circuit diagrams for signal inputs 144 Main circuit for signal inputs NPN 145 Main circuit for signal inputs PNP START PLC OUT PLC IN LABEL ROTARY ENCODER OD CAP A B 24 V PLC_IN_A PLC_IN_K Masse NPN Sensor 24 V PLC_IN_A PLC_IN_K Masse PNP Sensor ...

Page 197: ...8 Output signals Pin assignment M12 socket female matching connector article no A8144 149 Input signals Pin assignment M12 socket male socket matching connector article no A8145 GND 24V OUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cylinder Airstream Support Vacuum Blow On GND GND GND GND 24 V n c Touch Down A Home A n c Touch Down K Home K Airstream Support 4 GND 3 Cylinder 2 8 Blow On 5 GND 6 Vacuum 1...

Page 198: ...the pneumatic cylinder of the applicator Active during the dwell time or until touch down Duration setable with SIGNAL INTERFACE APPLIC SIGNALS Dwell time Airstream Support Output Controls the airstream which presses the label against the applicator plate Active after the start signal until start of application cylinder Vacuum Output Controls the vacuum at the applicator plate Active after the sta...

Page 199: ...sed with pneumatic dispensing edge 3 Signal only at optional Applicator Interface For details about applicator types read the description of function SIGNAL INTERFACE APPLIC SIGNALS Applicator type on page 79 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...

Page 200: ... 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 ap plication 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 Star...

Page 201: ...tions t1 and t2 The duration t1 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 position 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...

Page 202: ...e application cycle ends when the home position 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 usually 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 dwel...

Page 203: ...ensing speed Airstream Support switching to low means 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 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 ...

Page 204: ...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 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 Offlin...

Page 205: ...to low means 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 Vacuum Offline Cycle Inhibit Touch do...

Page 206: ...to low means 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 Additional signals available with opt...

Page 207: ... of control signals over time for the setting Applicator type ASA 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 se...

Page 208: ...abel 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 Additional signals available with optional Applicator Interface Start signal Airstream support Blow on setable Cycle Inhibit Offline A C D B ...

Page 209: ...ibit input at the AI can be activated SIGNAL IN TERFACE ACTIVE INPUTS Inhibit signal Opt appl interf Warning In Input An external warning status can be signaled by OR link at the warning output Error In Input An external error status can be signaled by OR link at the error output Ready Output Active in dispensing mode online or online settings Not active in configuration mode offline inclusive err...

Page 210: ... dispense mod 162D 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 162C Error Output Signal active when an error message appears on the operator panel display Iout 500 mA 1 Dispense End Output Signal that can be u...

Page 211: ...s to the dropping slope of the inhibit signal 163 Example for setting combination A1B1 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 sig...

Page 212: ... slope causes the queue to be deleted Two of the products are matching both con ditions in this case the impact of the dropping slope counts 165 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 Produc...

Page 213: ...LS XLS 20x 256 272 02 2019 01 213 Electronics Description 166 Example of setting combination A2B2 A B A B Start signal Inhibit signal Product sensor Dispensing edge Product will be labelled Product will not be labelled ...

Page 214: ...2 board RS 232 Suitable connection cable to a PC D Sub9 1 1 connector socket extension cable Article number A1207 Connection for external operator panel The connector 48B allows for the connection of an external operator panel See chapter Connecting mounting the external operator panel on page 66 Pin Signal 1 4 6 connected 2 RxD 3 TxD 5 Ground 7 RTS 8 CTS 9 not used Tab 49 Pin assignment for RS 23...

Page 215: ... connection cable to a PC USB cable A B Article number 126738 USB host Only at Gen 2 CPU board Ethernet 52 Ethernet interface A Pin Signal 1 Vcc from the host detection if a connection is existing 2 Data 3 Data 4 Ground Tab 50 Pin assignment for USB interface Pin Signal 1 VCC 2 Data 3 Data 4 GND Tab 51 Pinout USB interface 1 2 3 4 A ...

Page 216: ...rmware implements a TCP IP protocol stack which means that the label ler needs an IP address for the network in addition to its MAC address IP addresses are always written in decimal format as 4 bytes separated by points e g 192 168 1 99 IP addresses are assigned by whoever runs the network generally a network administrator MAC and IP addresses originate from different protocol layers and are fund...

Page 217: ...haracters 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 IMPORTANT These addresses must be assigned with care ensuring they are unique on each machine Call in your network administrator Menu Function Description INTEFACE PARA NETWORK PARAM IP Addressassign Set to Fixed IP address or ...

Page 218: ...s The AI works as a mini PLC which can control almost any applicator type If an AI is installed the Menu SIGNAL INTERFACE AI BOARD SIGNAL appears in the function menu Retrofitting kit AI Article no A9516 Required connectors AI connector 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 Circuit diagrams ...

Page 219: ... supply is 24 W 1 A This is the sum of all sen sor supplies and of all switch outputs which are active at the same time 170 Main circuit for outputs PNP Quantity Value Note Supply voltage 24 V 10 VIL state 0 5 V VIH state 1 18 0 V 3 8 mA 26 4 V 5 7 mA 1 2 tdelay propagation delay 60 µs 3 tdebounce software debouncing 10 ms Tab 54 Switching level definitions for signal inputs Connection Maximalstro...

Page 220: ...utput 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 Power outputs Power outputs can directly drive loads Maximum admissible output current for each power output 0 5 A Imax over all outputs 1 A 1 Rise time 0 1 at 48 Ohm 2 Fall time 1 0 at 48 Ohm 3 5 V microcontroller output 24 V Lo...

Page 221: ... dwell time or until touch down Duration setable with SIGNAL INTERFACE AI BOARD SIGNAL Dwell time Cylinder Cylinder GND Vacuum Vacuum GND Airstream Support Airs Supp GND Blow On Blow On GND BTS BTS GND Reserved GND Reserved GND Reserved Home Touch Down Repeat Feed Reserved Start 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 31 A 32 K 33 A 34 K 35 A 36 K 22 24 V 37 A 23 GND 38 K 24 24 V 39 A 25 GND 40 K 26 2...

Page 222: ...arator BTS Active if a bad RFID tag is detected Is set back by the following action e g devaluating the bad tag Start Input Iin 6 mA Signal is generated by the product sensor Starts the dispensing application cycle Dispenser reaction time is higher than after a start signal at the M12 start input application for direct dispensing is not advisable CAUTION Initially this signal input is deactivated ...

Page 223: ...max 1 A Pin 43 Imax 100 mA 173 Position and pin assignment of the internal applicator connection CN 609 Feed Input Iin 6 mA Feeding of the label material as long as the signal is active at least one label is dispensed Signal name Function Start K 2 24 V 4 Reserved 6 GND 8 Reserved 10 1 Start A 3 GND 5 Reserved 7 Key 9 Reserved CN 402 ...

Page 224: ...en an error message appears on the operator panel display Error Error GND Warning Warning GND Ready Ready GND Cycle Cycle GND not used PLC start Inhibit OD sensor in 1 2 3 4 5 6 7 8 9 19 A 20 K 21 A 22 K 23 A 24 K 16 OD sensor 25 Offline 17 OD sensor GND 26 Offline GND 18 not used 10 24 V 11 GND 12 24 V 13 GND 14 24 V 15 GND PLC start A 2 Inhibit A 4 not used 6 OD sensor 8 24 V 16 GND 18 OD sensor...

Page 225: ...A Start signals are ignored while signal is active CAUTION Initially this signal input is deactivated The Inhibit signal input at the standard signal interface PLC mode is activated This setting can be changed with SIGNAL INTERFACE ACTIVE INPUTS Inhibit signal OD sensor in Input Iin 6 mA Connection for optional roll outer diameter OD sensor CAUTION Initially this signal input is deactivated The OD...

Page 226: ... 402 24 V Versorgungsausgänge Imax 100 mA Signal name Function Start Input Iin 6 mA Same function as Start signal see Pin assignment for applicator connection on page 221 Key Mechanic coding of the connector reverse polarity protection Reserved Input not applied Iin 6 mA 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 4 ...

Page 227: ...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 D s e n s o r i n ...

Page 228: ...te less severe status than error messages The labelling is not interrupted by a warning Warning can occur both in dispensing mode and in online setting mode Warning format 182 Example of a warning in dispensing mode Material low Warning text a short description of what has caused the warning Setting back a warning In dispensing mode Press the button works earliest with firmware versions 1 10 In on...

Page 229: ...isted as a general software error in the error directory occurs repeatedly please inform the manufacturer quoting the error number and explaining the circumstances in which it occurred Machine fails to start If no valid firmware is installed the startup of the machine ends with the following bootloader mes sage The missing firmware can now be loaded via the serial interface or from an USB stick Fo...

Page 230: ...er to the dispensing edge The resolution of the rotary encoder is set wrong Verify if the conveyor speed matches the speed which is displayed on the operator panel If not correct the resolution setting of the rotary en coder Material low Internal OD control Critical material roll diameter is reached Rew stop warn The backing paper rewinder is deactivated Setting with MACHINE SETUP Rewinder Operat ...

Page 231: ...232 interface receive error COM1 Overrun Press the button to ack nowledge 3001 RS232 Parity RS232 interface receive error COM1 Parity Press Online button to acknowl edge Check setting in labeler s function menu INTERFACE PARA COM1 PORT Parity and on host comput er 3002 RS232 Frame RS232 interface receive error COM1 Frame Press Online button to acknowl edge Check the setting in the labeler s functi...

Page 232: ...correct if necessary Press the button to confirm the error message 5002 Material end Material end if the internal OD control 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 error stop is set to On Check the operation of the labeler increase distance bet...

Page 233: ...rheating the machine Cable between CPU board and Motordriver board not properly connected 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 selec tion switch Switch the machine off wait 30 seconds and switch it back on If the error message...

Page 234: ... direction Rotary encoder turns for at least 100 mm in wrong direction Change the configuration of the ro tary encoder 5111 OD sensor error Occurs during operation with acti vated external OD control when the light barrier is interrupted or when no light barrier is connected The material roll has reached the critical roll diameter The dispens er will soon run out of label stock Be prepared to inse...

Page 235: ...ncer home pos Homeposition of the rewinder dancer arm could not be found Check if the sensor board of the dancer arm is connected properly Replace the sensor board 5143 Rewinder Stop This message appears when the dancer arm was held against its upper stop for more than two sec onds Effect Power to the rewinder motor is switched off so that the rewinder can be turned easily by hand This effect is h...

Page 236: ...Check the settings on both ma chines See Setting up tandem operation on page 114 5151 Applic interf Applicator interface is missing or not connected Connect and or install applicator interface 5152 Winding direct The backing paper end is not cor rectly attached to the rewinder mandrel Wrong machine type selected MACHINE SETUP Dispenser type Attach the backing paper web to the rewinding mandrel as ...

Page 237: ...gain after half a minute If the error continues to occur after switching on and off several times please contact our technical sup port 5207 5208 5209 5210 Appl driver x x 1 4 Short circuit or over temperature at power output x of the applicator inter face AI Check connections 5212 Vx x for AI rec Wrong firmware for applicator inter face AI installed Install AI firmware version x x 5250 PLC Out ov...

Page 238: ...econds and switch it back on Please contact the manufacturer if the error message appears re peatedly 6030 New Parameters New firmware was loaded with the re sult that new functions have been added to the menu Press the button to acknowl edge Automatic reset is performed All parameters are reset to their factory settings 6031 Param checksum The parameter checksum is incorrect 6200 Filesystem regis...

Page 239: ...beler boots up but cannot be operated as part of a network Contact technical support Replace the CPU board if neces sary 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 manufac ture of the labeler Press the online button to ac knowled...

Page 240: ...art Switch machine off and on again after 30 s If the message contin ues to appear check power sup ply 9100 Invalid format Format error in download data e g invalid data format invalid checksum invalid address invalid record type Check and modify download data Restart machine 9101 Invalid header Format error in the dowload data header Check and modify header of download data Restart machine 9102 I...

Page 241: ...ce information in the header of the download data Check and modify download data Restart machine 9122 Checksum error Checksum error while loading a firm ware file The checksum of the loaded data doesn t match the calculated checksum Repeat the download If the error continues to occur the file is probably damaged or cor rupted Check exchange the firm ware file 9123 Memory unavailable Error while lo...

Page 242: ...e a change between 1 and 0 If no change takes place Adjust the sensor MACHINE SETUP Sensor Adjust 00 02 Starts Photoelectric product sen sor 1 or 0 Breaking the light beam must cause a 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 ...

Page 243: ...witch between 0 and 1 00 11 OD 2 Sensor for pressure roller 00 12 Matdiam OD sensor xx xx mm Displays the diameter of the material roll as currently calculated 00 13 L DancAr Not used 00 14 Option1 00 15 Option2 00 16 DancerR Position sensor for rewind unit dancer arm xxx yyy xxx Value of absolute dancer arm position dancer arm not initialized The differ ence between the positive and negative valu...

Page 244: ... 244 00 21 RewDanc xx Shifting of the two dancer arm encoder signals in related to period time Can be used for encoder adjustment during machine production Rated value 50 Sensor ID Name Value Test Tab 58 Overview for the MACHINE SETUP Sensor Test ...

Page 245: ...ing switching off the mains supply It tells the machine CPU to store important parameter settings For this purpose a sufficient voltage supply is available If this output 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 switc...

Page 246: ... next to the D Sub connector at the CPU board connector plate D502 Green LED 185A next to the 10pin connector at power supply D204 Green LED 186A near the 10pin connector on the CPU board D502 indicates 2 5 V which are generated out of 5 2 V 184 LED A indicating correct logic voltage at the CPU board 185 LED A indicating correct logic voltage at the power supply 186 LED A indicating correct logic ...

Page 247: ...ctor The following LEDs indicate that the PLC voltage appies properly Yellow LED 187A next to the 15pin D Sub connector at the CPU connector plate D901 Yellow LED 188A close to the 10pin connector on the CPU board D901 187 LED A at the CPU board indicating the correct PLC voltage 188 LED A indicating the correct PLC voltage on the CPU board A A ...

Page 248: ...re available The following LEDs indicate that the motor voltage applies properly 75 V Green LED 189B next to the small inductor on the motordriver board D203 17 V Green LED 189A next to the big inductor on the motordriver board D405 indicates 3 3 V which are generated out of 17 V 189 LED A indicating the correct motor voltages A B ...

Page 249: ...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 ap prox 1...

Page 250: ...thermore the Warning output is activated both earliest with firm ware 1 33 The machne does not stop If the warnng is ignored and no steps are taken to decrease the tempera ture the outputs 24 V and 17 75 V are switched off as soon as a critical overtemperature is reached The logic voltage for the CPU is kept upright An error message appears on the display The machine stops earlilest with firmware ...

Page 251: ...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 190 Pin assignment connector C 191 Connections at power supply A8171 10 8 6 4 2 1 3 5 7 9 Housing A A C D E B ...

Page 252: ...cket driver SW 2 5 and 3 Unscrew four screws 192A arrows Remove the cover box 192A off carefully By doing so the power connector on the inside of the cover box is removed If the cover box for interfaces 192B is prevailing If prevailing Pull the Ethernet connector off from the cover box Unscrew four screws 192B arrows Remove the cover box 192B carefully While doing so unplug the interface cables fr...

Page 253: ... if necessary 193 Housing with dust splash guard Positions of the sealings A G and cover boxes H I Opening the casing at machines held in place by side plate or base plate Prerequisites The machine is secured via a flange attached to the side plate or base plate 194 The machine is de energised Tools Hexagon socket driver SW 2 5 Remove 11 screws 195 Completely remove the two part casing rear wall A...

Page 254: ...Service Manual ALS XLS 20x 256 272 02 2019 03 254 Repair 194 Labeler ALS 20x held in position via flange attached to base plate 195 Fastening screws on rear wall of ALS 20x casing small picture ALS 256 ...

Page 255: ...n socket driver SW 2 5 Remove all 17 hexagonal drive screws 197 Remove both halves of the casing rear wall ALS XLS 256 272 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 197 squares 196 Labeler ALS 20x held in position vi...

Page 256: ...XLS 20x 256 272 02 2019 03 256 Repair Overview Screws holding the casing rear wall 197 Positions of the screws to be removed from the casing rear wall Long hexagonal drive screws 13 pcs Short hexagonal drive screws 4 pcs ...

Page 257: ...n Remove fan 199C and fan guard 199D The installation is performed in reverse order During the installation pay particular attention to the following Install the fan so that it blows outwards arrow flow direction The spare fan is delivered with extension cable Put the delivered extension cable aside if the installed extension cable is supposed to be used If an applicator interface AI is installed ...

Page 258: ...Service Manual ALS XLS 20x 256 272 02 2019 03 258 Repair 199 Removing the fan C A B C D ...

Page 259: ... installation is performed 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 200A Remove three screws 201B on the front side of the sleeve 201A Fully unscrew knob 201C complete with sleeve by turning it to the right left hand thread Remove front...

Page 260: ...rings into the expanding mandrel 206 Allow the adhesive bond to set Installing the unwinding spool Install unwinding spool with brake loosened Install shim 207B 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 suit...

Page 261: ...rectly adjusted swivel dancer arm anti clockwise about 20 The brake shoes must open and allow free rotation of the expanding mandrel 209E Install support disc and core adapters The retaining screws 209D on the rotary axles of the brake shoes are screwed into square nuts 210B The square nuts are located in a recess in the steel brake flange and brace against its side 210arrow There is therefore no ...

Page 262: ...t 212B may fall backwards out of flange Ball bearing 212A may fall out of brake shoe Carefully fit new brake shoe Do not touch brake lin ing surfaces 212arrow with bare hands and keep the surfaces free of grease Be careful of bolt 212B and ball bearing 212A Install circlips and tension spring Release brake by swivelling dancer arm and install expanding mandrel Set play at the brake cam see previou...

Page 263: ...ive 213 Removing toroidal transformer is not required with ALS XLS 256 272 Completely removing dancer arm Open the casing see chapter Opening the casing on page 252 Remove unwinding spool see chapter Expanding mandrel on page 259 ALS XLS20x Disconnect the plug connections 213C E Loosen the cable fasteners remove the cable from its guides 213D ALS XLS20x Remove nut 213B steel disc rub ber discs and...

Page 264: ...ut 217B remove cable bushing Remove 2 screws 217C on lever plate 217A Remove shaft complete with brake Disconnect plug connection 218C on unwind unit sensor Remove 2 nuts 218B remove the unwind unit sen sor together with its PCB 218A 218 Disconnecting plug connection and removing unwind unit sensor 215 Disconnecting plug connection removing bushing 216 Dancer arm removed from machine A Brake B Sha...

Page 265: ...19D securing nuts 219B with Loctite 243 Fol low the threadlock manufacturer s instructions for use Connect the plug connections 219C Fit washer disc 220B 221B to ball bearing 220A in dancer arm using grease 221 Assembly of brake dancer arm casing and lever plate 219 Unwind unit sensor with plug connection and cable bushing 220 Washer disc between ball bearing and lever plate D C B A A B A B C D E ...

Page 266: ...the brass bushing loosely into the thread plate on the rear side of the dancer arm casing Alternative B3 221G Screw washer ball bearing and stell bushing loosely into the thread plate on the rear side of the dancer arm casing Fix control lever in correct mounting position Se cure the brass bushing respectively ball bearing steel bushing in the marked position in the dancer arm casing 222A 2 Older ...

Page 267: ...ues from 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 226A flush with contact sur face 226 surface shaded grey in dancer arm Push in spacer ring Glue second ball bearing 226C into the dancer arm The ball bearing should be p...

Page 268: ... Insert cable bushing with O Ring 228A from the in side of the dancer arm and screw tight Grease the brass bushing 230C and guideway in the control lever 230B well When doing so ensure brake linings remain free of grease Fix control lever in correct mounting position Se cure the brass bushing in the marked position in the dancer arm casing 230A 230 Mount control lever in its prescribed mounting po...

Page 269: ...ancer arm into casing Ensure that the pin 233B on the front side of the casing mates with the hole 233A 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 231A for unwind unit sensor 231 Fitting bushing connecting plug connector 232 Cleaning the shaft s internal thread 233 Pin must mate with hole...

Page 270: ...dal transformer and all other components around it Pay particular atten tion to the distance from the power supply unit cas ing 235B ALS XLS20x Slide on second rubber disc and steel disc Screw toroidal transformer into place with nut 236A ALS XLS20x Connect the plug connections 236B D Fit cable into guides 236C and secure with ca ble fasteners Install unwind spool and adjust axial play of unwind s...

Page 271: ...ear during measurement of tractive force Hook on force measurement device 237 Pull on the force measurement device until the dancer arm swivels and the brake releases Specified value for pulling force 8 10 N Adjust restoring force as required Turn the adjusting screw 238A on the dancer arm left to increase restoring force Turn the adjusting screw 238A on the dancer arm right to decrease restoring ...

Page 272: ...Repair Replacing dancer arm springs 239 The two spring types in the dancer arm Tools Hexagon socket driver SW 2 5 Hook for hanging out the tension spring The dancer arm is equipped with two springs a tension spring 239A and a pressure spring 239B A A B ...

Page 273: ...isc 243 Three of those are marked with locking varnish Remove those 3 screws that are not marked with locking varnish and remove the support disc 243 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 242A 240 Removing the core adapters 241 Removing the support disc fig ALS 20x 242 Tension spring A at t...

Page 274: ...ing holder 247A Pull the spring holder downwards 245 248 Remove the spring 246 Installation The installation is performed in reverse order After the installation pay particular attention to the following action Adjust the restoring force tab 1 of the dancer arm see Ch Adjusting restoring force of dancer arm on page 271 247 Plug the hex socket screwdriver A into the set screw B at the spring holder...

Page 275: ...ed roller unit ALS XLS 20x 256 Feeding is done by one single feed roller 250 251 ALS XLS 272 Feeding is done by a pull and a push feed roller 252 Both rollers are coupled by a toot hed belt on the operator side of the machine This chapter contains instructions for the following Removing feed roller unit on page 276 Replacing ball bearings in casing on page 279 Installing feed roller on page 279 7 ...

Page 276: ...oller is the same with all machines Open the casing see chapter Opening the casing on page 252 Loosen cable fastening 253B Remove the 2 screws 256A from the front side holder of the motor driver board Remove the holder 256B Loosen the 2 scews at the rear side holder Remove motor driver board 256C and disconnect all 4 cables 253 Drive of the feed roller in ALS 20x A A A 255 Cable fastening A of the...

Page 277: ...emove pulley 259A and toothed belt 259B Remove circlip 259C and shim 259D On the opposite side of the machine fold the pres sure roller out of its working position 260 Continued overleaf 257 Screws A holding the feed motor in place 258 Set screws A at the pulley picture showing ALS 272 259 Removing the feed roller E 260 Folding the pressure roller downwards A B A A B C D E ...

Page 278: ...ller 261C loo sen the screw 262B at the inner end of the excen ter axle Turn the excenter axis by applying a spanner at the outside end 262A of the axle until the toothed belt is slack Pull the feed roller and shaft 263 out of the casing 261 ALS XLS 272 Toothed belt B between the feed rollers A and C 262 ALS XLS 272 Excenter axis at the front feed roller cross section 263 Removed feed roller ALS 2...

Page 279: ... bearings into the casing The ball bear ings 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 266arrow with an oil stone as necessary Lightly grease the part of the feed roller shaft that has contact with the bearings 267B but keep the feed roller itself 267A free from grease In...

Page 280: ...rew 268B to bevel then tighten sec ond setscrew Slide the motor 270A until the toothed belt is taut Tighten 3 screws on the motor mount Connect and install the motor driver board 270D Connection diagram see chapter Wiring Diagrams on page 156 ff Fasten motor lead to housing with cable fastening 270E ALS XLS 272 Tighten the toothed belt 271C bet ween the two feed rollers To do so turn the excen ter...

Page 281: ...e Adjusting toothed belt tension Open the casing see chapter Opening the casing on page 252 Loosen 3 fastening screws for the motor 272A Slide the motor until the belt 272B is taut then retighten 3 screws on motor mount 272 Holding screws A at the feed motor A B ...

Page 282: ...screws 274A from the front side holder of the motor driver board Remove the holder 256B Loosen the 2 scews at the rear side holder Remove motor driver board 274C and disconnect all 4 cables Loosen the 3 screws on the motor 275A to slacken the toothed belt 275B Continued overleaf 273 Fastening A of the motor cable 274 Removing the motor driver board C A A B C 275 Holding screws A at the feed motor ...

Page 283: ...lley 276A 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 re move motor 277C 276 Toothed belt pulley on the feed roller shaft fig shows ALS 272 277 Removing the feed motor C A A B C ...

Page 284: ...ulley in order to align one of the two setscrews 279B with the bevel in the motor shaft 279arrow Aligning belt pulley and toothed belt with motor pin ion The toothed belt must run in the centre of the belt pulley and motor pinion ALS XLS 256 272 The belt pulley is positioned fur ther outside on the shaft approx 1 5 mm behind the shaft end Tighten setscrew to bevel then tighten second set screw Adj...

Page 285: ... differs in the following points from the roller at ALS XLS 20x and ALS XLS 256 281B labellers narrower rollers only 1 ball bearing in the roller equipped with ball be aring s Tools Hexagon socket driver SW 2 5 3 5 Hot air blower Auxiliary materials Loctite 648 adhesive Loctite 243 Threadlocker Multi purpose grease 281 Pressure rollers both RH for ALS XLS 20x 256 B and for ALS XLS 272 A ...

Page 286: ...s of the steel roller Allow the adhesive bond to harden fully Place steel roller with washer discs in pressure roller assembly and slide in the axle 283D with the con tact surfaces 283arrows for the pressure pins fac ing 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 284arrow Scre...

Page 287: ...or driver board in place Remove motor driver board 286B and disconnect all 4 plug connections 286C Remove screw 287A 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 hou...

Page 288: ... ALS 204 Measurement A 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 289B on front ends of the cone follower inserts 289A Remove the cone follower inserts Remove one of the synthetic binders 290 Remove the spool hub segments 291 A t 4 20 8 30 20 289 Removing cone follow...

Page 289: ... use Installing 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 293C 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 293A and screw it flush to the front end of the h...

Page 290: ...ot be compressed when the release button is pushed in Loosen the 3 setscrews 305B on front cone 305A Slide the cone fractionally towards the machine cas ing and tighten the setscrews Take care not to over tighten the setscrews Check the expansion mechanism is functioning properly Repeat adjustment procedure as neces sary ...

Page 291: ...l available Dismantle the expanding mandrel at the machine see chapter Exchanging the complete expanding mandrel on page 291 Exchanging the spring Remove the complete expan ding mandrel read the following chapter Exchanging the complete expanding mandrel Tools Hex socket screwdriver 2 5 mm Remove the support disc 296A To do so turn out the 3 screws 296B Loosen the set screw 297A on the aluminium d...

Page 292: ...ding mandrel 299A onto the re winder axis and turn it so that the pin ends 299B engage in the recesses 299C of the aluminium disc Tighten the set screw The set screw must engage in the groove 299D at the height of the pin Screw on the support disc again 298 Removing the expanding mandrel from the rewinder axis 299 Installing the expanding mandrel A A B C B C D ...

Page 293: ...screw 301C Remove the button 301D Unscrew the cover 302B 6 screws 302A Remove the rail 303A and the 3 bars 303B The expanding mandrel cannot be disassembled fur ther from this side For further disassembly completely remove the expansion mandrel as described in the pre vious chapter Assembly The assembly is performed in reverse order Pay par ticular attention to the following Mounting position of t...

Page 294: ...tite 648 adhesive Loctite 243 Threadlocker Multi purpose grease Removing the dancer arm Remove expansion mechanism see Ch Expand ing mandrel ALS 2xx Remove the three screws 306A remove the sup port disc 306B Open the casing see Ch Opening the casing Loosen 4 screws on the motor mount 307A to slacken the toothed belt 307C Loosen 2 setscrews on the large pulley 307B Remove pulley and toothed belt 7 ...

Page 295: ...move 2 screws 309B and remove the perforat ed plate 309A Remove circlip 309C and shim 309D Pull out dancer arm 308B forwards complete with shaft 308A Be careful of shim and dancer arm spring 308E Pull shaft out of dancer arm Smooth dents in the shaft 309arrow with an oil stone as necessary B A D C C D E 309 Removing the perforated plate D A B C ...

Page 296: ... no spacer 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 bear ings 311A using a hot air blower Remove ball bearings and spacer rings 311B Remove adhesive residues from the bearing seats Fixing the ball bea...

Page 297: ...rm 314B and push shaft complete with dancer arm all the way in Inside the casing slide shim 315E over end of shaft and install circlip 315D Ensure circlip engag es 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 suit able shim Installing the perforated plate Guide the perforated plate 315A into the photo electric sensor...

Page 298: ...arrow Aligning belt pulley and toothed belt with motor pin ion The toothed belt must run in the centre of the belt pulley and motor pinion Tighten setscrew 317B to bevel then tighten sec ond setscrew Slide the motor 317D until the toothed belt is taut Tighten 4 screws on the motor mount 317A Installing remaining parts Install casing rear wall Install support disc 318A When doing so make sure the a...

Page 299: ...C Carefully introduce the photoelectric sensor with bracket into the machine casing Take care that the perforated plate 320A does not damage the photo electric sensor Screw in the screws 320C 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...

Page 300: ... driver board in place Remove motor driver board 324A and disconnect the plug connections 324B to E Loosen 4 screws on the motor mount 322A to slacken the toothed belt 322C 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 322B Loosen 2 setscrews on the motor pinion 322F Remove toothed...

Page 301: ...ling toothed belt and pulley Place the toothed belt 327B over the motor pinion 327A Slide belt pulley 327E 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 327Arrow Aligning belt pulley and toothed belt with motor pin ion The toothed belt must run in the centre of the belt pulley and motor pi...

Page 302: ... Follow this installation instruction Click START DEVICES AND PRINTERS ADD PRINTER Click ADD A LOCAL PRINTER In the dialog Choose a printer port select STANDARD TCP IP PORT alternativley USB PORT if a USB line is connected 328 Click NEXT 328 Choose a printer port Enter the IP address of the machine into the field HOSTNAME OR IP ADDRESS 329 Click NEXT IP adddress see SCHNITTST PARA NETZWERK PARAM I...

Page 303: ... Device Type choose STANDARD and GENERIC NETWORK CARD 330 Click NEXT 330 Entering information about the device type Enter GENERIC as manufacturer and GENERIC TEXT ONLY as printer 331 Click NEXT 331 Choose a printer driver Enter a printer name 332 Click NEXT ...

Page 304: ...rinter Enter a share name 333 Click NEXT The Share name must match MS DOS conventions max 8 characters length no special char acters or spaces 333 Defining a share name Done The machine can be addressed now be means of the share name see Download via data interface on page 130 ...

Page 305: ...ntil both LEDs 334C shine equally bright base adjustment Move the label web through the sensor fork and watch the switching output LED The LED 334C must shine in label gaps If case of insufficient switching behaviour change the sensitivity setting After increasing the sensitivity setting the base adjustment must be repeated 334 Capacitive label sensor LEUZE GK14 24 A LED display switching output B...

Page 306: ...lized be means of the Excel file ALS20x_Ramping xls The file is stored in the Labeller_and_Pan dA Utilities folder on the documentation CD Service Using the calculation sheet Open the file ALS20x_Ramping xls 335 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 335A Read the calculation results 335B ...

Page 307: ...together the max dis pensing speed is not reached at all In this case the note max speed not reached appears in the results field total time for dispensing Required time for dispensing one label theoretical max performance Theoretical max label rate This value can also be determined graphically see chapter Label rate on page 28 Diagrams of performance data Out of the input values the calculation s...

Page 308: ...Service Manual ALS XLS 20x 256 272 02 2019 01 308 336 Graph of the dispensing speed over the dispensing duration after the following inputs label length including gap 26 mm max dispensing speed 40 m min ...

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Page 312: ...Novexx Solutions GmbH Ohmstraße 3 85386 Eching Germany 49 8165 925 0 www novexx com ...

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