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Operators Manual

ALS 330/430

Release 8/07

Page 29

Operation

4.2.7

Adjust pressure roller

Depending on the application the foam roller has to be adjusted. Loose the both screws and
tighten the screws again after the adjustment was done.

Figure 14 Adjust pressure roller

4.3

Initializing new label material

The machine requires data of the label material in use i.e. label length and opacity of the label
and backing material. In most cases, those parameters can be scanned during automatic
initialisation. This is not always possible.
During initialisation, the machine uses its label sensor to determine where the labels are on the
label web and the distance between the leading edge of labels (the label pitch) so that they can
be positioned correctly.

There are several modes of initialisation:

y

Automatic mode: The machine measure the setting

y

Manual mode: The operator measures the label parameter and keys in the values.

In most cases, initialisation should be executed in fully automatic mode. For fully automatic
initialisation, the "LPIT" and "CONT" parameters should be set to "AUTO". Initialisation can be
executed by pressing the <FEED key> whenever the message "INIT" is displayed by the
machine.

The message "INIT" is displayed in the following cases:

a) if the <FEED> key is pressed and held during power up
b) on return to the standard menu after the "CONT" or "LPIT" parameters have been changed

to automatic mode

c) on return to the standard menu after the configuration menu has been used
d) after clearing the error messages E__0 or E__1 in the standard menu. (If the feed key is

pressed while another parameter is displayed, the data from the last initialisation is held
and the first label edge detected is simply moved to the position defined by the "STOD"
parameter)

To start initialisations simply press the <FEED> key when "INIT" is displayed.
The machine will slowly feed the label web while it searches for the gaps between labels and
measures the label pitch. When the machine has determined this information it will move the

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Содержание ALS 330

Страница 1: ...Ausgabe 08 07 Artikelnummer 0089999 06...

Страница 2: ......

Страница 3: ...e environmental regulations 10 2 Description 11 2 1 Mechanics 11 2 2 Operator panel 13 2 3 Plug board 14 2 4 Electronics 15 3 Preparing the machine 17 3 1 Installation 17 3 1 1 Unpacking of the unit 1...

Страница 4: ...5 1 Standard menu 39 5 2 Extended standard menu 41 5 3 Product menu 47 6 Configuration menu 43 6 1 Handling the menu 44 6 2 Menu functions 45 7 Serial interface 51 7 1 Data of the serial interface 51...

Страница 5: ...73 9 1 Dispenser error messages 73 9 2 Dispenser warnings 75 10 Technical specification 77 10 1 Technical Information 77 10 1 1 Application specification 78 10 1 2 APSF Sensor Specification Optional...

Страница 6: ...Operators Manual ALS 330 430 Release 8 07 Contents...

Страница 7: ...e version 7 0 For technical questions particularly in case of problems your local service organisation will be pleased to help you 1 1 1 Manufacturer This machine was built by Avery Dennison Deutschla...

Страница 8: ...tion EN 292 and 294 1 2 2 Warning Notes in the Text In this description two types of notes can be found y Warning note indicates a possible risque of injury for the user Ignoring the warning can lead...

Страница 9: ...ose cf the section Use in accordance with the purpose in the chapter Specification the machine is only operated in faultless serviceable condition and that especially the safety devices are regularly...

Страница 10: ...njury This symbol indicates that especially danger to the machine material and the environment has to be expected The most important aim of the security regulations is to avoid injuries to a person Wh...

Страница 11: ...oved from the operating area of the machine Before every production start up it must be checked and made sure that all safety devices function in a correct manner 1 2 6 Security measures during mainte...

Страница 12: ...sis even if there is no damage to be detected Observe the manufacturers instructions Before setting into operation after maintenance or repair works check if loosened screwed connections are tight mak...

Страница 13: ...e label sensor 15 is mounted It detects the gap between the labels The sensor includes a light source and a light receiver The software can adjust the sensitivity With this information the machine cal...

Страница 14: ...Release 8 07 Page 12 Description Figure 1 Machine layout Apart from the drive roller 1 and the material brush 6 the labeller has no mechanical wearing parts The operator panel 19 is described in the...

Страница 15: ...ine An initialisation has to be made each time a new material is used If the FEED key is pressed and held as the machine is turned on then the machine carries out an automatic initialisation of the la...

Страница 16: ...tions Standard execution in this machine is one I O plug prepared for the product sensor The connection of the other plugs is described in chapter Connections If you use the optional connections it is...

Страница 17: ...in the machine For special requirements water protection e g a machine version the electronic is housed in a separate cabinet is available As standard the complete electronic is integrated in the mach...

Страница 18: ...Operators Manual ALS 330 430 Release 8 07 Page 16 Description...

Страница 19: ...parts on the machine Do the necessary actions to prevent that anybody can be caught from these parts 3 1 2 Connection of the machine Before connecting the machine to the mains check the correct settin...

Страница 20: ...R simultaneously Display CODE y Password CODE entering 1 time pressing the key PRIOR FUNCTION 2 times pressing the key NEXT FUNCTION 3 times pressing the key ENTER Display LPIT y Setting the label len...

Страница 21: ...ve a label from the backing paper and slide it inside the sensor y Reduce the value with the PRIOR key until the LED switched on y Press the key NEXT until the LED switched off If there are marks an t...

Страница 22: ...sensor is carried out as follows Figure 5 1 Set sensitivity to maximum by turning the Potentiometer clockwise Then rotate turn anticlockwise 2 Remove label material out of sensor 3 Perform base adjust...

Страница 23: ...sition Dispense speed Label position on the product The adjustment should be done in the same order because parameter like the stop position depends on the setting of the stop position and the dispens...

Страница 24: ...ttle bit higher than your product speed 3 4 3 Automatic dispensing speed APSF With a connected rotary encoder the dispensing speed follows the measured product speed To adjust the speed use the EGRA f...

Страница 25: ...on CAUTION y Before connections to the mains check the correct voltage selection y Use only original spare parts for service y Open of the cover is only allowed authorised personal y Handling of the m...

Страница 26: ...terial the waste paper should be removed CAUTION Isertion exchange of material should be carried out only by especially instructed personal Threading of the label material is shown down below on the t...

Страница 27: ...material Turn the lever the expanding pads retract The roll of backing material can easily be pulled off the rewind mandrel Figure 8 Remove label material To ensure a reliable function of the unwind i...

Страница 28: ...psible key can be moved further in or out for clamping and releasing the label roll Figure 10 Unwind unit at ALS 430 The material brush has to be positioned in a way that the material is kept tight Fr...

Страница 29: ...roller and the rewind mandrel Figure 11 Rewind 4 2 3 Adjusting the pressure roller The pressure roller should always be positioned over the middle of the backing material This ensures accurate label p...

Страница 30: ...scale on the dispensing edge bars 4 2 5 Adjustment of the dispensing edge Loosen handle 1 and 2 and turn lead screw Z Once the adjustment is completed pull the handles tight again Figure 13 Dispensing...

Страница 31: ...n the values In most cases initialisation should be executed in fully automatic mode For fully automatic initialisation the LPIT and CONT parameters should be set to AUTO Initialisation can be execute...

Страница 32: ...rning on the mains switch and at the same time pressing one of the panel keys you may select between several options PANEL KEY mains switch Function Display message FEED Material initialisation INIT N...

Страница 33: ...he message by pressing the key ENTER and you will get back to the status the machine was in before the error was indicated Note Data entered in the standard menu are not stored if the machine is switc...

Страница 34: ...e position of the label can be changed by the parameter POS while the machine is in operation The display is presented in 1 10 mm and means the distance between product sensor and labelling position o...

Страница 35: ...to assure accurate labelling A change of the product speed causes a different position of the label on the product In case of inaccurate labelling it should be verified if the speed of the dispenser a...

Страница 36: ...or measures the diameter of the material roll and indicates a warning message W__5 as the label roll diameter gets too small i e there are only a few labels left on the label roll To the warning outpu...

Страница 37: ...Operators Manual ALS 330 430 Release 8 07 Page 35 Operation...

Страница 38: ......

Страница 39: ...production can be changed here The adjustments are lost after turning off the machine Extended standard menu This menu offers additional parameters and functions to those in the standard menu Any adj...

Страница 40: ...IT ON OFF Direct LPIT PD01 DTST INIT ON OFF CONT PD02 P_S_ POS SENS PD03 MACH STOD STOD PD04 MDIR VELO PRDL PD05 MLAB POS PD06 APSF Applicator STAD PD07 APPL INIT ON OFF VELO PD08 I_CH STAD STST PD09...

Страница 41: ...ration OFF Stop labelling operation INIT Initialisation of label sensor and label pitch detection After status of E__0 and E__1 only POS Position of label on the product Up to 999 9 mm STOD Stop posit...

Страница 42: ...osition of the label once the label edge has reached the dispensing edge The STOD value defines the actual stop position of the label in steps of 0 1 mm With this adjustment the label can be made to s...

Страница 43: ...shown below Display Function Data value LPIT Label pitch AUTO 5 999 mm CONT Label sensor contrast value AUTO 1 200 SENS Sensor status LAB or GAP STOD Stop position of label at the dispensing edge 0 0...

Страница 44: ...a distance of 111 mm was measured M111 The manual mode is selected and a length of 111 mm was entered Range AUTO or 5 999 mm Label contrast __________________________________________________ CONT With...

Страница 45: ...ks or edges Such a case is shown below The product sensor supplies several signals while the product passes the product sensor If the PRDL is not adjusted according to the dimension of the actual prod...

Страница 46: ...match Slew speed _____________________________________________________ SLEW Function For some situations the labeller can run with a different higher speed This occurs during compensation of a missing...

Страница 47: ...ore possible 60 ms to 100 ms depending on the length of the air cylinder To calculate the correct value proceed as follows Set APT4 to 1 Run the conveyor at a fairly low speed such as 10 m min and not...

Страница 48: ...lection this function you can save the current parameter setting to a data bank Always available Range NEW1 NE15 Create a new data bank PD01 PD15Overwrite existing data bank EXIT Leave function withou...

Страница 49: ...to a new product bank the machine assumes the label roll has been changed or that a parameter such as STOD is different and so requires an initialisation of the label position at the dispensing edge...

Страница 50: ......

Страница 51: ...he interface Possible tests y In output test y Test run without labelling The function Factory initialisation resets all parameters to default values Calling the configuration menu There are two ways...

Страница 52: ...els P_S_ Product sensor detects at leading or trailing edge of product LEDG TEDG MACH Machine type 230 720 330 430 MDIR Motor running direction for left or right hand MLAB Handling of missing label NO...

Страница 53: ...he trailing edge of a product is used Reasons for detecting the leading edge can be shape of product your should avoid detecting a radius or a declined edge In case of using other than the standard pr...

Страница 54: ...d EGRA setting and so any EGRA value works just as well At slow speeds the label dispense speed matches the conveyor speed exactly regardless of the EGRA setting For instance if the dispenser needs to...

Страница 55: ...e switch active E Applicator end switch active Z Horizontal home switch Block 3 inactive S pressure switch activated J Jumper 3 closed O OD control material active M Label sensor on material G Label s...

Страница 56: ...machine is delivered with the interface the baud rate is set to 9600 Select your baud rate by pressing the key NEXT or PRIOR With the key ENTER the adjustment is stored Factory adjustment NONE Parity...

Страница 57: ...is shown in steps of 0 1 mm e g 0456 means 45 6 mm The measured value can be adjusted by pressing the key FUNCTION If the DIST value has been adjusted correctly the first leading label edge detected...

Страница 58: ...430 Release 8 07 Page 50 Configuration menu Note Modified parameter values are only stored if the menu is left by using the QUIT function If the power is switched off before leaving the menu by quit a...

Страница 59: ...reception of the character indicates the start of a new command to the machine The codes are similar to the parameter names shown in the display 7 1 Data of the serial interface The pin connection of...

Страница 60: ...ns VELO0300 04H Command Description Range APOSnnnn Value APOS 0050 0100 mm APPLnnnn Applicator type 0000 direct dispense 0001 ASA 0002 EP 0003 EP_U 0004 PLUA 0005 INDX APSFnnnn APSF function 0000 off...

Страница 61: ...9999 0 1 mm VELOnnnn Speed 0020 0300 0 1m min SAVEnnnn Store in data bank 0001 0009 LOADnnnn Load data bank 0001 0009 The following described commands do not have parameter values With these commands...

Страница 62: ...or description 0 E__0 Pressure roller open 1 E__1 End of material 4 missing labels 2 E__2 EP applicator error 3 E__3 checksum error configuration data 4 E__4 checksum error parameter bank 5 E__5 Error...

Страница 63: ...he wiring of the terminal is shown otherwise 8 1 1 Error and warning output The outputs for errors and warnings are available on the terminal CN33 and optional on the I O plug The signals are switched...

Страница 64: ...nal motor run signal could be behind the start of the dispense motor adjusted with the function APT3 The signal is switched inactive when the label dispense has been completed Also the stop could be a...

Страница 65: ...me period APT2 defines how long the blow on signal is active After labelling the product and the time period of APT3 a new label will be dispensed on to the applicator After that the machine is ready...

Страница 66: ...erated After the delay time APT1 the blow on valve is switched active for the time APT2 When APT2 is completed both the labelling cylinder valve and the blow on valve signals are switched inactive If...

Страница 67: ...Manual ALS 330 430 Release 8 07 Page 59 Connections and signals 8 2 4 Applicator connector The applicator connection is done via a 15 pole D sub connector common to other machines Figure 20 Applicator...

Страница 68: ...als from the HOME and END switches y an unused input for future extensions or customer specific software used for loop control in the 720 The inputs are galvanically separated through photo couplers t...

Страница 69: ...imum distance is necessary for the internal speed compensation The machine is supplied as standard with one socket for connecting the product sensor You may either use a NPN or PNP type sensor output...

Страница 70: ...form the personal that in the next time the material has to be changed 24V GND 14 black green white red brown 5 9 4 8 3 7 2 6 1 Signal GND Signal Supply white grey blue 25 11 27 CN33 E3JK R2M2 NPN sen...

Страница 71: ...roduct movement The connection of the encoder should be done with a shielded cable For correct operation the rise and fall time of the encoder signal should be 1 s 24V GND 14 black yellow white red 5...

Страница 72: ...9 4 8 3 7 2 6 1 5 9 4 8 3 7 2 6 1 CN33 red green black schwarz rot gr n 24 Volt 24 Volt Ground Masse Warning output Warnausgang Error output Fehlerausgang Inhibit Startunterdr ckung Inhibit Startunte...

Страница 73: ...Operators Manual ALS 330 430 Release 8 07 Page 65 Connections and signals l Figure 29 Internal I O connector...

Страница 74: ...ule 5 On all inductive components relays valves must be directly connected a clamp circuit diode MOV Rule 6 All signal lines must be shielded The shield must have a good earth connection on both sides...

Страница 75: ...Operators Manual ALS 330 430 Release 8 07 Page 67 Connections and signals 8 5 Electronic diagrams...

Страница 76: ...Operators Manual ALS 330 430 Release 8 07 Page 68 Connections and signals Figure 30 Wiring diagram...

Страница 77: ...Operators Manual ALS 330 430 Release 8 07 Page 69 Connections and signals Figure 31 Layout dispenser electronic board...

Страница 78: ...LED Voltage Ready LED Overtemperature 100 on Short circuit 25 on 75 off Both 75 on 25 off Direction Direction NC NC Clock Ready Collector Ready Emitter 48VAC 48VAC Phase1B Phase1A 800 400 Resolution...

Страница 79: ...Operators Manual ALS 330 430 Release 8 07 Page 71 Connections and signals...

Страница 80: ......

Страница 81: ...tage has fallen below specification The message STO store indicates that the machine has stored some parameters internally as a power fail condition was detected The error output is switched active an...

Страница 82: ...LED s on the driver E__9 10V supply for label sensor too high Voltage regulator U14 damaged E__10 Missing label on product One or several product could not be labelled Distance between products too cl...

Страница 83: ...speed or product sequence Adjust higher labelling speed Increase the parameter value of PRDL product length W__2 Error while writing in the EEPROM EEPROM defect Start machine again if problem remains...

Страница 84: ...Operators Manual ALS 330 430 Release 8 07 Page 76 Errors and warnings...

Страница 85: ...nwind brake for minimum change in web tension Euro versions only Dispensing speed 0 2 25 m min 0 2 18 m min Material transport 0 1 mm per motor step APSF Automatic Product Speed Follower optional Reso...

Страница 86: ...ion The resolution of the sensor should be selected in a way that for 0 15mm product travel a sensor pulse will be generated Using a different resolution gives loose in label accuracy or limits the hi...

Страница 87: ...label and product dimensions reduce the label rate The charts are valid for direct dispensing without applicator and printer For critical applications performance test should be done first The charts...

Страница 88: ...cal specification 0 5 10 15 20 25 30 m min labels min 0 100 200 300 400 500 600 700 800 900 1000 1100 25 mm 50 mm 75 mm 100 mm 150 mm 250 mm Figure 35 Performance chart Ramp NORM 0 5 10 15 20 25 30 m...

Страница 89: ...specification 0 5 10 15 20 25 30 m min mm 0 1 2 3 4 5 6 7 8 Normal Fast Figure 37 Deceleration 10 2 2 Charts 430 0 5 10 15 20 25 30 m min labels min 0 100 200 300 400 500 600 700 800 25 mm 50 mm 75 mm...

Страница 90: ...hnical specification 0 5 10 15 20 25 30 m min labels min 0 100 200 300 400 500 600 700 800 900 25 mm 50 mm 75 mm 100 mm 150 mm 250 mm Figure 39 Performance chart Ramp NORM 0 5 10 15 20 25 30 m min mm...

Страница 91: ...Operators Manual ALS 330 430 Release 8 07 Page 83 Technical specification 0 5 10 15 20 25 30 m min mm 0 1 2 3 4 5 6 7 8 9 10 Normal Fast Figure 41 Deceleration...

Страница 92: ......

Страница 93: ...330 430 Release 8 07 Page 85 Adjustment 11 Adjustment Function Factory Application P_S_ LEDG MACH 230 MDIR RAMP FAST MLAB WARN COMP ON APSF OFF APPL DIR BAUD NONE PARI NO SBIT 2BIT DBIT 8BIT DIST 76...

Страница 94: ...ry PD01 PD02 PD03 PD04 POS STAD 100 0 mm VELO 30 0 m min STOD 76 0 mm BLOW APT2 1 ms LPIT AUTO CONT AUTO PRDL AUTO EGRA 500 APT1 200 ms APT3 0 ms APOS 0 ASTP 0 PDT OFF Function PD05 PD06 PD07 PD08 PD0...

Страница 95: ...58 Extended standard menu 37 F factory values 48 I interface 48 51 L Label counter 49 Labelling position 53 M MACH Siehe Machine type Machine type 45 missing label 45 O OD control 62 OD Control 55 Out...

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