Avery Dennison ALS 380 Operating instructions

ALS

380

OPERATING MANUAL

Label Dispenser

Article number: A6392, Release 06.2005

1

CONTENTS

ALS

380

1 Please observe the following

1.1 General information . . . . . . . . . . . . . . 4

1.1.1 Validity and applicability of this manual . . . . . 4

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical State . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright notice . . . . . . . . . . . . . . . . . . . . . . . . . 4

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1.2 Conventions and information . . . . . . . . . . . . . 5

Explanation of symbols . . . . . . . . . . . . . . . . . . . . 5

Warnings concerning dangers and risks . . . . . . . 5

Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Supplemental information . . . . . . . . . . . . . . . . . . 5

Directional information. . . . . . . . . . . . . . . . . . . . . 6

1.2 Safety instructions . . . . . . . . . . . . . . . 7

1.2.1 Information and qualifications . . . . . . . . . . . . . 7

Pay attention to the information. . . . . . . . . . . . . . 7

Information must be made available . . . . . . . . . . 7

Ensure necessary qualifications . . . . . . . . . . . . . 7

1.2.2 Machine operating safety . . . . . . . . . . . . . . . . 8

Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Protect against injuries that can result from

electrical current . . . . . . . . . . . . . . . . . . . . . . . . . 8

Protect against injuries that can result from

mechanical actions . . . . . . . . . . . . . . . . . . . . . . . 8

Protection against chemicals. . . . . . . . . . . . . . . . 8

1.2.3 Before every production start . . . . . . . . . . . . . 9

Operator's obligation and service personal to

exercise care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating personnels' obligation to exercise

care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Equipment description

2.1 Overview . . . . . . . . . . . . . . . . . . . . . 10

2.1.1 Structural elements . . . . . . . . . . . . . . . . . . . . 10

2.1.2 Principle of operation . . . . . . . . . . . . . . . . . . 11

2.1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . 12

Characteristic values . . . . . . . . . . . . . . . . . . . . . 12

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . 12

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . 12

Control system . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.4 Design versions . . . . . . . . . . . . . . . . . . . . . . 13

Top-labeller right-hand version . . . . . . . . . . . . .13

Side-labeller right-hand version. . . . . . . . . . . . .13

Top-labeller left-hand version . . . . . . . . . . . . . .14

Side-labeller left-hand version . . . . . . . . . . . . . .14

2.1.5 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

High-speed processing version ALS 380 HS . .15

Serial interface. . . . . . . . . . . . . . . . . . . . . . . . . .15

Roll diameter control . . . . . . . . . . . . . . . . . . . . .15

Adjustable dispensing edge. . . . . . . . . . . . . . . .15

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.2 Operator controls . . . . . . . . . . . . . . . 16

2.2.1 Operator panel . . . . . . . . . . . . . . . . . . . . . . . 16

LED indicator . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.2.2 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Control system . . . . . . . . . . . . . . . . . 18

2.3.1 Brief description . . . . . . . . . . . . . . . . . . . . . . 18

2.3.2 Menus for operators and calibration

technicians . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3.3 Monitoring functions. . . . . . . . . . . . . . . . . . . 20

Dispensing a label to each product . . . . . . . . . .20

Label supply . . . . . . . . . . . . . . . . . . . . . . . . . . .20

If errors occur . . . . . . . . . . . . . . . . . . . . . . . . . .20

3 Prior to operating

3.1 Insert the labelling material . . . . . . . 21

3.1.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1.2 Insert the label roller. . . . . . . . . . . . . . . . . . . 21

Remove the old backing material . . . . . . . . . . .21

Remove adhesive residues . . . . . . . . . . . . . . . .21

Insert new label roll . . . . . . . . . . . . . . . . . . . . . .22

3.1.3 Threading the label ribbon . . . . . . . . . . . . . . 23

Overview of the threading path diagram . . . . . .23

Thread the label ribbon at the unwind unit. . . . .24

Thread in the label ribbon at the dispensing

edge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Thread the label ribbon at the rewind unit. . . . .26

CONTENTS

2

CONTENTS

ALS

380

3.2 Mechanical settings . . . . . . . . . . . . . 27

3.2.1 Setting the ribbon guides . . . . . . . . . . . . . . . 27

Operator panel support . . . . . . . . . . . . . . . . . . . 27

Deflection rollers on the rewind unit . . . . . . . . . 27

3.2.2 Adjusting the braking brushes. . . . . . . . . . . . 28

3.2.3 Adjusting the pressure rollers . . . . . . . . . . . . 29

3.2.4 Adjust the pressure roller unit (optional) at

the dispensing edge.. . . . . . . . . . . . . . . . . . . 30

3.2.5 Adjust (optional) the position of the

dispensing edge.. . . . . . . . . . . . . . . . . . . . . . 31

Adjusting vertically. . . . . . . . . . . . . . . . . . . . . . . 31

4 Operation

4.1 Activation and shut-down. . . . . . . . . 32

4.1.1 Starting the machine . . . . . . . . . . . . . . . . . . . 32

Automatic material initialisation . . . . . . . . . . . . . 32

Manually initialise the material . . . . . . . . . . . . . 33

4.1.2 Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Start dispensing labels . . . . . . . . . . . . . . . . . . . 35

Unwind unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Rewind unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.1.3 Stop/end the label dispensing. . . . . . . . . . . . 36

4.1.4 Tandem operation. . . . . . . . . . . . . . . . . . . . . 37

Principle of operation. . . . . . . . . . . . . . . . . . . . . 37

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Start dispensing labels . . . . . . . . . . . . . . . . . . . 38

Reloading label material . . . . . . . . . . . . . . . . . . 39

Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2 Setting and monitoring. . . . . . . . . . . 41

4.2.1 Settings in the standard menu . . . . . . . . . . . 41

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Calling up menu . . . . . . . . . . . . . . . . . . . . . . . . 41

Call up function . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.2.2 Label stop position (STOD). . . . . . . . . . . . . . 42

4.2.3 Dispensing speed (VELO) . . . . . . . . . . . . . . 43

Automatic dispensing speed (optional) . . . . . . . 43

4.2.4 Label position on the product (POS). . . . . . . 44

4.2.5 Automatic material initialisation (INIT) . . . . . 45

4.2.6 If errors occur . . . . . . . . . . . . . . . . . . . . . . . . 46

4.3 Product databanks . . . . . . . . . . . . . . 48

4.3.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3.2 Loading product data banks. . . . . . . . . . . . . 48

Please observe:. . . . . . . . . . . . . . . . . . . . . . . . .48

Activating product databanks at switch-on . . . .49

Activating product databanks after switch-on . .49

4.3.3 Create/save product databank . . . . . . . . . . . 50

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Saving the product databank. . . . . . . . . . . . . . .50

Documenting product databanks. . . . . . . . . . . . 50

4.3.4 Deleting a product databank . . . . . . . . . . . . 51

4.4 Settings in the extended menu. . . . . 52

4.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.4.2 Activating an extended menu. . . . . . . . . . . . 54

Please observe:. . . . . . . . . . . . . . . . . . . . . . . . .54

Calling up menu. . . . . . . . . . . . . . . . . . . . . . . . .54

Call up function . . . . . . . . . . . . . . . . . . . . . . . . .54

Exit the extended menu. . . . . . . . . . . . . . . . . . .54

4.4.3 Position of second label (POS2) . . . . . . . . . 55

4.4.4 Position of third label (POS3). . . . . . . . . . . . 55

4.4.5 Speed ratio (VERT) . . . . . . . . . . . . . . . . . . . 56

4.4.6 Adjust the label stop sensor (CONT) . . . . . . 57

Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Automatically adjusting the photoelectric

sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Manually adjusting the sensor. . . . . . . . . . . . . .58

4.4.7 Label distance (LPIT) . . . . . . . . . . . . . . . . . . 59

Check setting. . . . . . . . . . . . . . . . . . . . . . . . . . .59

4.4.8 Distance from the label stop sensor to the dis-

pensing edge (E–SS) . . . . . . . . . . . . . . . . . . 60

Set distance. . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Check setting. . . . . . . . . . . . . . . . . . . . . . . . . . .61

4.4.9 Product length (PRDL) . . . . . . . . . . . . . . . . . 62

4.4.10 Polarity of the product sensor (P_S_) . . . . . 63

4.4.11 Polarity of the label stop sensor (S_S_). . . . 63

4.4.12 Number of unlabelled products (MLAB). . . . 64

4.4.13 Electronic transmission ratio of the

RPM transmitter (EGRA) . . . . . . . . . . . . . . . 64

4.4.14 Advance print start (PDT). . . . . . . . . . . . . . . 65

4.4.15 Printer dwell time (PDWT) . . . . . . . . . . . . . . 65

4.4.16 Tandem operation (TMOD) . . . . . . . . . . . . . 66

3

CONTENTS

ALS

380

4.4.17 Applicator type (APPL) . . . . . . . . . . . . . . . . . 66

4.4.18 EP cylinder dwell time (APT1) . . . . . . . . . . . 66

4.4.19 Blowing time (APT2) . . . . . . . . . . . . . . . . . . . 66

4.4.20 Delay time (APT3). . . . . . . . . . . . . . . . . . . . . 66

4.4.21 Fine tuning of the dwell time (APT4). . . . . . . 66

4.4.22 Delete a product data bank load (LOAD) . . . 66

4.4.23 Create/save product data bank (SAVE) . . . . 66

4.4.24 Delete a product data bank (DEL) . . . . . . . . 66

4.5 Automatic dispensing speed

(APSF). . . . . . . . . . . . . . . . . . . . . . . 67

4.5.1 Electronic transmission ratio of the

RPM transmitter (EGRA) . . . . . . . . . . . . . . . 68

Setting the compensation factor . . . . . . . . . . . . 68

Test the setting:. . . . . . . . . . . . . . . . . . . . . . . . . 68

4.6 Applicator (optional). . . . . . . . . . . . . 69

4.6.1 Principle of operation . . . . . . . . . . . . . . . . . . 69

4.6.2 Functions in the extended menu. . . . . . . . . . 70

Please observe the following. . . . . . . . . . . . . . . 70

Calling up the extended menu. . . . . . . . . . . . . . 70

Applicator type (APPL) . . . . . . . . . . . . . . . . . . . 70

EP cylinder dwell time (APT1). . . . . . . . . . . . . . 71

Blowing time (APT2) . . . . . . . . . . . . . . . . . . . . . 71

Delay time (APT3) . . . . . . . . . . . . . . . . . . . . . . . 71

Fine tuning of the dwell time (APT4) . . . . . . . . . 72

5 After operation

5.1 Care and cleaning . . . . . . . . . . . . . . 73

5.1.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . 73

5.1.2 Regular maintenance . . . . . . . . . . . . . . . . . . 73

Remove paper waste. . . . . . . . . . . . . . . . . . . . .74

Braking brushes. . . . . . . . . . . . . . . . . . . . . . . . .74

Capacitive sensor at the dispenser head . . . . .75

6 Operational malfunctions

6.1 Warning messages. . . . . . . . . . . . . . 76

6.1.1 Please observe: . . . . . . . . . . . . . . . . . . . . . . 76

6.1.2 If a problem occurs. . . . . . . . . . . . . . . . . . . . 76

6.1.3 Warning messages . . . . . . . . . . . . . . . . . . . 76

6.2 Error messages . . . . . . . . . . . . . . . . 78

6.2.1 If a malfunction occurs . . . . . . . . . . . . . . . . . 78

6.2.2 Error codes. . . . . . . . . . . . . . . . . . . . . . . . . . 78

7 Appendix

7.1 Factory settings . . . . . . . . . . . . . . . . 82

7.2 Product data banks . . . . . . . . . . . . . 84

7.3 EC Declaration of Conformity. . . . . . 86

4

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

ALS

380

1.1.1 Validity and applicability of this manual

Contents

The present manual refers exclusively to the ALS 380

Labeller and the high-speed ALS 380 HS version. The

manual is to be referred to for correct operation and ad-

justment of the machine.

The prerequisites for operation and adjustment are

proper installation and configuration of the machine.

For technical questions which are not addressed in this

operating manual:

➔Refer to the Service Guide for the ALS 380 Labeller

or

➔consult the servicing technician of our sales partner.

– The responsible servicing technician of our sales

partner is at your disposal and particularly helpful

with configuration settings and remedying malfunc-

tions.

Technical State

Technical state as of: 06/2005

Software versions

ALS 380: 6.1

ALS 380 HS: Master 1.1, Slave 1.0

Avery Dennison reserves the right to:

– implement modifications of structural parts, compo-

nents and software as well as to use equivalent

components that keep pace with the current state of

technology in lieu of the specified components.

– change information contained in this manual.

An obligation to extend these modifications to previous-

ly delivered machines is excluded.

Copyright notice

All rights to this operating manual are assigned to Avery

Dennison. Transmission, reprinting or any other means

of reproduction of this manual, whether whole or in part,

are not allowed without prior written permission. Third

parties, in particular competitors, are not to be allowed

access to information derived from this manual.

Printed in Germany

Manufacturer

Avery Dennison Deutschland GmbH

Ohmstraße 3

D - 85386 Eching

Phone: +49-8165-925-0

FAX: +49-8165-3143

http://www.machines.averydennison.com

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

5

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

ALS

380

1.1.2 Conventions and information

Explanation of symbols

In order to facilitate legibility and an overview, the vari-

ous types of information used herein are categorised

and identified with certain symbols.

Sentences that are introduced by an arrow contain pro-

cedural instructions.

➔Carry out procedural instructions one after the other

in the prescribed order.

The following information is introduced with a dash:

– List items

– Descriptions of conditions

– Description of previous work steps

– Prerequisites for implementing actions described in

the following passage

Warnings concerning dangers and risks

Important text passages which must absolutely be fol-

lowed are particularly marked for special attention:

DANGER!

A danger notice indicates an imminent

hazardous situation which, if not avoided,

could result in death or serious injury of the

personnel!

The notice contains instructions on how to

avoid or prevent the danger(s).

➔The instructions must be followed.

WARNING!

A warning notice indicates risks which could

result in death or serious injury of the

personnel! The notice contains safety in-

structions on how to safeguard possibly af-

fected personnel.

➔The instructions must be followed.

CAUTION!

A caution notice indicates risks which, if

unheeded, could lead to material damage or

bodily injury (minor injuries). The notice

contains instructions on how to prevent

damage or injury.

➔The instructions must be followed.

Illustrations

When required, text passages are accompanied by il-

lustrations. The reference to an illustration is indicated

by typesetting the [illustration number] in square brack-

ets. Capital letters following an illustration number, e.g.

[12A], refer to the corresponding position indicated in

the illustration.

Supplemental information

The "Experts" symbol earmarks activities that

only to be performed by knowledgeable and

trained personnel.

The information symbol indicates notices and

recommendations as well as additional helpful

information.

Operating materials:

– Operating materials, e.g. lubricants or

cleaning agents

6

1PLEASE OBSERVE THE FOLLOWING

1.1 GENERAL INFORMATION

ALS

380

Directional information

Unless otherwise indicated, the directional information

mentioned in the text refers to the construction of the

right-hand version of Top Labeller. See Figure [1] for

the explanation of directional information.

[1] Definition of directional information

AFront

BRear

CUpward

DDownward

ELeft

FRight

GClockwise

HCounter-clockwise

A

B

C

D

E

F

G

H

7

1PLEASE OBSERVE THE FOLLOWING:

1.2 SAFETY INSTRUCTIONS

ALS

380

1.2.1 Information and qualifications

Pay attention to the information

WARNING!

Reliable and safe operation of the labeller is

only guaranteed if all necessary information

is observed!

➔Read this operating manual thoroughly

and observe all notices prior to operation.

➔Observe all additional safety and warning

notices attached to the labeller.

➔Only allow qualified persons to operate

and adjust the labeller.

Information must be made available

This operating manual

➔is to stored at the machine operating location and

made accessible to the operator.

➔is to maintained in legible condition.

➔is to be made available to the new owner if the ma-

chine is sold.

➔Safety and warning notices attached to the labeller

must be kept clean and legible. Missing or damaged

warning labels and plates are to be replaced.

Ensure necessary qualifications

➔Only allow the machine to be operated, adjusted

and serviced by instructed and authorised person-

nel.

➔Adjustment tasks via the expanded menus as well

as programming and administration of product data-

bases are only to be performed by qualified and ap-

propriately trained personnel or by the responsible

servicing technician.

➔The responsibilities for operation, adjustment and

servicing of the machine must be clearly defined

and consistently maintained.

➔Moreover, personnel are to be regularly instructed

about work safety and environmental protection is-

sues.

Operator qualifications

Instruction of the operating personnel must ensure:

– that operating personnel can use the machine inde-

pendently and without posing a danger.

– that operating personnel can remedy minor opera-

tional malfunctions themselves.

➔Train at least 2 person to operate the machine.

➔Make label materials for test purposes available in

sufficient quantities.

Qualifications for adjustment tasks

Settings in the expanded menus of the control

software require knowledge based on experi-

ence:

– The adjustment personnel must be familiar

with how the labeller functions.

– Adjustment personnel must be familiar with

the entire system into which the labeller is in-

tegrated.

– Adjustment personnel must be able to cor-

rectly apply the functions in the expanded

menu system to appropriately address the

order-specific requirements.

1.2 SAFETY INSTRUCTIONS

8

1PLEASE OBSERVE THE FOLLOWING:

1.2 SAFETY INSTRUCTIONS

ALS

380

1.2.2 Machine operating safety

Appropriate use

The ALS 380 labeller is a fully automatic machine for

the application of self-adhesive labels to products or

packages. The machine is to be equipped by the oper-

ation planners with suitable safety devices so as to pro-

tect the operating personnel from possible

endangerment – e.g. pinching or entrapment of body

parts due to reaching between product and dispensing

edge.

WARNING!

Improper usage of the machine can lead to

accidents, material damage and loss of pro-

duction!

➔Only operate this machine in accordance

with information contained in this manu-

al.

➔Do not put the machine into operation

without the required safety equipment in

place.

➔Only make adjustments to the machine in

accordance with this manual and with all

due care.

Protect against injuries that can result

from electrical current

WARNING!

The machine is connected with the mains

supply! Contact with energised components

can result in life-endangering currents

through the body as well as burns.

➔Only put the machine into operation when

installed in a correctly installed housing.

– The housing may only be removed by

trained personnel when the machine is

de-energised.

➔Pull out the mains power connection plug

from the socket before cleaning and

maintenance.

The machine is not protected against

splashing water.

➔Maintain the machine in a dry condition.

➔In case fluids penetrate into the machine

interior, immediately switch off the ma-

chine and disconnect or plug out from the

mains power supply. Notify a servicing

technician.

Protect against injuries that can result

from mechanical actions

WARNING!

Risk of injury due to moving or rapidly rotat-

ing parts!

➔The following regulations always apply:

➔Keep a distance from running machines. Wear

snug-fitting clothing and hair nets.

➔Even when the machine is idle, maintain the area

clear of movable parts if the possibility exists that

the machine could start.

➔Never lay tools or loose parts on the machine if the

possibility exists that the machine could start.

➔Switch off the machine before performing mechani-

cal adjustment tasks.

➔Do not wear ties, loose garments, jewellery, watch-

es or similar articles on the body when in the ma-

chine vicinity.

CAUTION!

Danger of body part trapping and pinching at

the dispensing edge due to products moving

in the conveyor direction!

➔Never reach between the product and dis-

pensing edge of running or operation-

ready machines.

➔During operation, never remove or defeat

the purpose of protective guards that pre-

vent reaching into the machine.

Protection against chemicals

CAUTION!

Operational materials such as cleaning

agents or adhesive solvents may pose a

health risk.

➔Rules, work guidelines and safety regula-

tions issued by the manufacturer must

absolutely be followed!

9

1PLEASE OBSERVE THE FOLLOWING:

1.2 SAFETY INSTRUCTIONS

ALS

380

1.2.3 Before every production start

Operator's obligation and service personal

to exercise care

➔Ensure the following prerequisites correspond to the

information of the operating manual:

– The machine is correctly installed and appropriately

configured for the requirements.

– All necessary safety equipment is installed.

– The machine has successfully completed at least

one test run.

– The machine is connected to the power supply.

➔The required personal safety gear, e.g. hair nets,

must be provided. Make sure that the safety gear is

used in accordance with the regulations.

Operating personnels' obligation to exer-

cise care

➔Verify flawless functioning of the safety equipment.

➔Check machine for visible damage. Any discovered

deficiency is to be reported immediately.

➔Use personal safety gear in accordance with the

regulations, e.g. wear hair nets.

➔Non-required materials and objects are to be re-

moved from the working area of the machine.

➔Make sure that only persons authorised to work on

the machine are within the working area of the ma-

chine.

➔Make sure that no one will be placed in a hazardous

situation as a result of the machine startup.

10

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

2.1.1 Structural elements

[2] Right-hand version of the ALS 380 Labeller

B

G

C

AD

E

I

H

K

L

M

N

O

F

J

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

11

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

A Unwind unit

– The unwinding spindle holds the label roll.

– The spreader mechanism (chucking wedge) se-

cures the label roll.

B Dancer arm of the unwind unit

– spring-loaded and rotatable

C Guiding rod for unwind unit

– Also secures the label roll.

D Drive roller unit of the unwind unit

E Pressure roller of the unwind unit

F Braking brush up

– Allows label ribbon to run smoothly, prevents flutter-

ing.

GCasing

– Houses the control electronics, drive electrical sys-

tem, main switch, and fuses.

H Mounting brackets

– For securing the machine in the system.

I Operator panel

J Braking brush down

K Dispenser head

– With integrated label feed

– Optionally equipped with printer or applicator

L Dispensing edge

– The label separates from the backing material here.

M Rewind unit

– An electrically driven rewinding roller takes up the

empty backing material.

– A spreader mechanism secures the backing materi-

al roll.

N Dancer arm of the rewind unit

– spring-loaded and rotatable

O Deflection rollers of the rewind unit

2.1.2 Principle of operation

In labelling mode, the unwind unit [2A] and the drive

roller unit move the [2D] label ribbon. A loop is formed

in the label ribbon between the pressure roller of the un-

wind unit [2E] and the upper braking brush [2F]. An ad-

ditional drive roller unit in the dispenser head [2K] pulls

the ribbon over the dispensing edge [2L]. The label

separates from the backing material at the dispensing

edge.

The drive roller unit in the dispensing head moves the

respective ribbon for a label and then stops until the

next product takes the label under the dispensing edge.

Label ribbon is continuously unwound at the unwind

unit. The loop acts as a buffer between the continuous-

ly operating unwind unit and the periodically operating

label output. The braking brushes keep the label ribbon

taut.

From the dispensing head, the empty backing material

runs over several deflection rollers [2O] to the mo-

tor-driven spreaderrewinding unit [2M]. The multiple

deflections with the spring-loaded dancer arm [2N] act

as a buffer between the label output and the rewind

unit.

The entire operation of the labeller is electronically con-

trolled and monitored. If a malfunction occurs, the con-

trol system sends a corresponding message to the

operator. If necessary, the labelling operation is auto-

matically halted. An electronic signal is issued at the

same time. The signal can be picked up by an external

control system.

12

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

2.1.3 Technical data

Characteristic values

Labels

1) Longer labels are possible when product distance is increased accordingly

Ambient conditions

Dimensions

Casing

Electrical system

1) Customer options

Control system

Emissions

Dispensing speed

ALS 380:

ALS 380 HS:

0.5 m/min to 80 m/min

0.5 m/min to 100 m/min

Stop accuracy (at the

dispensing edge): ± 0.5 mm

Rewind unit: Spreader mechanism

Label sensor: Manual or automatic set-

ting

Operation: programmable, can be set

via the operator panel,

The settings can be stored

in 11 data banks

Speed control: Automatic dispensing

speed, with RPM-

transmitter

Label width

(incl. backing material): max. 155 mm

Label length at

maximum dispensing

speed:

min. 16 mm

max. 250 mm 1)

Label roll

Outer diameter

Core diameter:

max. 400 mm

76.2 mm

Distance from dispens-

ing edge to label sen-

sor:

min. 20 mm

Temperature

Operation:

Storage:

5°C to 40°C

5°C to 70°C

Relative humidity: 30 % to 80 %,

not condensing

Dimensions

Width:

Height:

Depth:

735 mm

795 mm

400 mm

Weight

ALS 380:

ALS 380 HS:

50 kg

55 kg

Covering for the control-

electronics:

Polyurethane (PUR),

10 mm thick

Front plate: Aluminium, anodized,

15 mm thick

Power consumption: 500 VA

Mains connection

Nominal voltage:

Frequency:

110 V / 120 V / 130 V /

200 V / 220 V / 230 V/

240 V 1)

50 Hz / 60 Hz 1)

Type of protection IP41 (protected against

vertically falling drops of

water, not protected

against sprayed water)

Drive system: 2 stepping motors,

1 AC motor

Control electronics: Integrated

Options: V24 interface

Frequency inverter for

motor control

Sound pressure level at

a distance of 1 m: 75 db (A)

13

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

2.1.4 Design versions

The ALS 380 labeller is available in 4 different versions,

depending on the taskat hand:

Top-labeller right-hand version

– Labelling from above onto the upper side of the

product [3].

– The products are conveyed from left to right.

– The dispensing edge is located on the right side.

Side-labeller right-hand version

– Labelling from the side onto one of the product’s

sides [4].

– The products are conveyed from left to right.

– The dispensing edge is located on the right side.

[3] Top-labeller right-hand version

AALS 380 labeller

BProduct on conveyor line

CLabelled product

[4] Side-labeller right-hand version

AALS 380 labeller

BProduct on conveyor line

CLabelled product

A

B C

AB C

14

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

Top-labeller left-hand version

– Labelling from above onto the upper side of the

product [5].

– The products are conveyed from right to left.

– The dispensing edge is located on the left side.

Side-labeller left-hand version

– Labelling from the side onto one of the product’s

sides [6].

– The products are conveyed from right to left.

– The dispensing edge is located on the left side.

Labeller operation is described in these instruc-

tions based on the top-labeller right-hand de-

sign version.

Other design versions are only considered if

their descriptions or illustrations differ.

[5] Top-labeller left-hand version

[6] Side-labeller left-hand version

15

2EQUIPMENT DESCRIPTION

2.1 OVERVIEW

ALS

380

2.1.5 Options

High-speed processing version

ALS 380 HS

– Allows dispensing speeds up to 100 m/min

– Available in all of the above-mentioned design ver-

sions.

Serial interface

– Almost all of the setting values can be read out and

modified on an external device, the machine status

can be queried, and the machine can be controlled

via this interface.

Roll diameter control

– A sensor at the unwind unit monitors the diameter of

the label roll and, along with it, the supply of labels.

– The sensor sends a signal when the diameter of the

label roll reaches a set value.

– This sensor is required if two labellers are operating

in tandem mode (see chapter Operation - Activation

and shut-down, Tandem operation)

Adjustable dispensing edge

– The position of the dispenser head can be adjusted

vertically.

– This allows adapting the position of the dispensing

edge to changing products.

– The machine does not have to be moved to adjust

the dispensing edge. The labelling head of the ma-

chine does not have to be released.

Printer

– Inkjet or heat transfer printer at the dispenser head.

Applicator

If direct labelling from the dispensing edge is not possi-

ble, the labeller can be equipped with an applicator.

Various kinds of applicators are available depending on

the customer’s needs.

16

2EQUIPMENT DESCRIPTION

2.2 OPERATOR CONTROLS

ALS

380

2.2.1 Operator panel

LED indicator

– Display of functions, setting values, operating

states, error messages, and warning messages

If the LED indicator is ON:

– The machine is in labelling mode.

– Each time the product sensor is triggered, a label is

dispensed.

If the LED indicator is OFF:

– Labelling mode is switched off.

Keys

FEED

– When this key is pressed, the machine dispenses a

label.

PRIOR (previous function)

– Paging through the functions in the menu: to see the

previous function, page upward.

– Within a function: increase the current value

NEXT (next function)

– Paging through the functions in the menu: to see the

next function, page downward.

– Within a function: decrease current value

ENTER

– Activate or switch off labelling mode.

– Call up or end functions.

– Acknowledge error and warning messages.

Depending on the menu and the operating

state of the machine, special key functions are

also available. Where special functions are

available, they are described in the relevant

chapter.

[7] Operator panel for the ALS 380

ALED indicator

BFEED key

CPRIOR key

DNEXT key

EENTER key

A

B

C

D

E

2.2 OPERATOR CONTROLS

17

2EQUIPMENT DESCRIPTION

2.2 OPERATOR CONTROLS

ALS

380

2.2.2 Main switch

– The main switch [8] is located to the left on the

housing.

– The main switch is used to switch the machine on

and off.

WARNING!

Contact with energised components can re-

sult in life-endangering currents through the

body as well as burns. Voltage continues to

be present in the housing even when

switched off.

➔Only put the machine into operation when

installed in a correctly installed housing.

➔Maintain the machine in a dry condition.

[8] Main switch on the housing

A

18

2EQUIPMENT DESCRIPTION

2.3 CONTROL SYSTEM

ALS

380

2.3.1 Brief description

All of the machine’s functions are electronically

controlled. Using the operator panel, the operators, cal-

ibration technicians, or service personnel have several

options for adapting the machine's functions to current

requirements.

The LED indicator gives the operator feedback mes-

sages regarding the current operating state of the ma-

chine. Error messages or warning messages appear on

the display as necessary.

Before each operation, the operator must check and

adjust the occasionally changing settings such as the

label position on the product or the dispensing speed.

These settings can simply be input at any time by the

operator at the operator panel.

Task-specific data such as label distance or product

length are programmed at the beginning of a job. As a

rule, the settings are not modified as long as the job is

being processed. This data input requires in-depth

knowledge and may only be carried out by trained and

instructed personnel (calibration technicians).

Databanks are available for variable or frequently re-

curring task settings. The task-specific settings can be

saved in a databank. If the settings are needed again

after a product change, it is not necessary to re-input

the data. You only need to call up the corresponding

databank. In all, 11 databanks are available.

Only calibration technicians may administer the product

databanks.

It is also possible to modify the basic machine settings.

These are settings such as the motor’s direction of ro-

tation. These settings are not to be changed in normal

operation. They may only be changed by servicing per-

sonnel or the responsible servicing technician.

To give the operator a better overview, the setting op-

tions for occasionally changing settings, task-specific

data, databanks, and basic settings are grouped to-

gether in menus: The standard menu, extended menu,

product databanks, and configuration menu. The fol-

lowing table provides an overview of the range of func-

tions of the standard menu, extended menu, and

product databanks. The configuration menu is de-

scribed in the service guide.

CAUTION!

Erroneous settings can lead to production

setbacks, damage to the machine and sys-

tem, and can even cause work-related acci-

dents!

– Only specially trained and instructed per-

sonnel may alter the settings in the ex-

tended menu or access the product

databanks.

2.3 CONTROL SYSTEM

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Avery Dennison ALS 380 Operating instructions

Avery Dennison ALS 380 Operating instructions

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