Avery Dennison ALS 230 User manual

Release 12/07
A
rtikelnummer: 0089999-02

Operators Manual
ALS 230
Release 12/07 Page i Contents
Contents
1. Important Notes........................................................................................................4
1.1 Overview.......................................................................................................................................4
1.1.1 Manufacturer......................................................................................................................4
1.1.2 Copyright............................................................................................................................4
1.2 Safety............................................................................................................................................5
1.2.1 General Safety Notes ........................................................................................................5
1.2.2 Warning Notes in the Text.................................................................................................5
1.2.3 Operator’s duty of care......................................................................................................6
1.2.4 Concrete security regulations and symbols used.............................................................. 7
1.2.5 Security measures during normal operation......................................................................8
1.2.6 Security measures during maintenance and repairs.........................................................8
1.2.7 Work on the electrical equipment ...................................................................................... 9
1.2.8 Work on pneumatic equipment..........................................................................................9
1.2.9 Observe environmental regulations...................................................................................9
2. Description .............................................................................................................11
2.1 Mechanics ..................................................................................................................................11
2.2 Operator panel............................................................................................................................13
2.3 Plug board ..................................................................................................................................15
2.4 Electronic....................................................................................................................................15
3. Preparing the machine...........................................................................................17
1.1 Installation....................................................................................................................................17
1.1.1 Unpacking of the unit.........................................................................................................17
1.1.2 Connection of the machine................................................................................................17
1.1.3 General setting..................................................................................................................17
1.2 Prepare dispensing ......................................................................................................................17
1.2.1 Insert material....................................................................................................................17
1.2.2 Define label data................................................................................................................18
Capacitive label sensor ..............................................................................................................20
3.1 Label guide.................................................................................................................................21
3.2 Adjust dispense function.............................................................................................................21
Stop position...............................................................................................................................21
3.2.1 Fixed dispensing speed................................................................................................... 22
3.2.2 Automatic dispensing speed (APSF)...............................................................................22
3.2.3 Label position on the product...........................................................................................22
3.2.4 Product data bank............................................................................................................22
4. Operation ...............................................................................................................23
4.1 Safety recommendation..............................................................................................................23
4.2 Inserting label material ...............................................................................................................23
4.3 Initializing new label material......................................................................................................24

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4.4 Control of dispense unit..............................................................................................................25
4.4.1 Dispenser Menu selection................................................................................................25
4.4.2 Missing label function and web breaks............................................................................26
4.4.3 Display and data input......................................................................................................27
1.3 Maintenance.................................................................................................................................30
5. Menu structure.......................................................................................................31
5.1 Standard menu ...........................................................................................................................33
5.2 Extended standard menu............................................................................................................35
5.3 Product menu..............................................................................................................................41
6. Configuration..........................................................................................................45
6.1 Handling the menu......................................................................................................................46
6.2 Menu functions............................................................................................................................47
7. Serial interface.......................................................................................................53
7.1 Data of the serial interface..........................................................................................................53
7.2 Interface commands ...................................................................................................................54
7.2.1 Bit definition in error flag ..................................................................................................56
7.2.2 Bit definition in warning flag .............................................................................................56
8. Connections and signals........................................................................................57
8.1 Output signals........................................................................Fehler! Textmarke nicht definiert.
8.1.1 Error and warning output.............................................Fehler! Textmarke nicht definiert.
8.1.2 Printer output...............................................................Fehler! Textmarke nicht definiert.
8.1.3 OD-Control output.......................................................Fehler! Textmarke nicht definiert.
8.1.4 Ready output...............................................................Fehler! Textmarke nicht definiert.
8.2 Applicator modes...................................................................Fehler! Textmarke nicht definiert.
8.2.1 Signals for direct dispense..........................................Fehler! Textmarke nicht definiert.
8.2.2 Control signals for the ASA applicator........................Fehler! Textmarke nicht definiert.
8.2.3 Signals for the EP applicator.......................................Fehler! Textmarke nicht definiert.
8.2.4 Applicator connector ...................................................Fehler! Textmarke nicht definiert.
8.3 Input signals...........................................................................Fehler! Textmarke nicht definiert.
8.3.1 Product sensor............................................................Fehler! Textmarke nicht definiert.
8.3.2 OD Control sensor ......................................................Fehler! Textmarke nicht definiert.
8.3.3 APSF sensor...............................................................Fehler! Textmarke nicht definiert.
8.3.4 Control signals ............................................................Fehler! Textmarke nicht definiert.
8.4 EMI.........................................................................................Fehler! Textmarke nicht definiert.
8.5 Electronic diagrams ....................................................................................................................70
9. Errors and warnings...............................................................................................73
9.1 Dispenser warnings ....................................................................................................................75
10.Technical Specification ..........................................................................................77
10.1Technical Information..................................................................................................................77
10.2Application specification..............................................................................................................78

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10.3APSF- Sensor Specification (Optional function) ........................................................................78
10.4Performance...............................................................................................................................79
10.4.1Labels per minute in relation to different label pitches....................................................79
10.4.2Dispensing speed reached while dispensing certain label length...................................80
11.Adjustment.............................................................................................................83
12.Index ......................................................................................................................85

Operators Manual
ALS 230
Release 12/07 Page 4 Important Notes
1. Important Notes
1.1 Overview
The AVERY ALS 230 is a fully automatic labeller. Handling is very easy and can be learned
with a minimum of training. For operation, only a few adjustments are necessary. The machine
is controlled by a microprocessor and because of its programmable functions, it can be used in
many applications.
Except for cleaning the rollers and the label sensor there is no periodical maintenance
necessary. This manual should help you to operate the ALS 230. In chapter 2 the machine is
described and many expressions are explained. For normal operating chapters 3 and 4 are
important. All other chapters give additional details of the machine.
For technical questions, particularly in case of problems, your local service organisation will be
pleased to help you.
Note: This manual applies to ALS 230s equipped with firmware version 7.0.
1.1.1 Manufacturer
This machine was built by: Avery Dennison Deutschland GmbH
Ohmstraße 3
85386 Eching
Germany
Tel. 08165-(0)925-0
FAX 08165-(0)-3143
1.1.2 Copyright
© 2007 Avery Maschinen GmbH. All rights reserved. No part of this work covered by Avery 's
copyright may be reproduced or copied in any form or by any means (graphic, electronic or
mechanical, including photocopying, recording, recording taping, or information and retrieval
systems) without the written permission of Avery Maschinen GmbH. Avery also reserves all
other rights, including the right to make changes or corrections at any time without notice.
Avery make no representation or warranties about the accuracy, currency, completeness or
suitability of the information provided herein and will not be held liable for any use of this
information for any purpose. It is provided "as is" without express or implied warranty.

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1.2 Safety
1.2.1 General Safety Notes
In order to avoid any risk of injury due to squeezing between the fixed dispensing edge and the
passing product, it may be necessary to add a protection cover in front of the dispensing edge.
The necessity for this has to be decided on case by case.
See also regulation EN 292 and 294.
1.2.2 Warning Notes in the Text
In this description, two types of notes can be found:
yWarning note – indicates a possible risque of injury for the user. Ignoring the warning can
lead to injuries or material damages.
Example:
CAUTION! - The machine is connected to mains. Only authorised
personnel may open the cover. Operation without this cover is not
allowed.
ySpecial advice regarding the carrying out – please notice!
Example:
Note: Please take note of the given notes and advices. They serve your safety
as well as the preservation of value of the machine.

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1.2.3 Operator’s duty of care
The machine was designed and constructed taking into account a
hazard analysis and after careful selection of the harmonised
standards to be observed, as well as other technical specifications.
Thus, it corresponds to the state of the art and allows the highest
possible degree of safety during operation.
The safety of the machine, however, can only be put into operating
practice if all measures required for the safety are taken. It falls within
the operator‘s duty of care to plan these measures and to verify their
implementation.
Above all, the operator must make sure that
•the machine is only used in accordance with its purpose (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 checked with
respect to their serviceability
•the required personal protective clothing and equipment for
operating, maintenance and repair personnel are available and
are being used
•a legible and complete copy of the operating instructions is always
available at the place of operation of the machine
•only personnel which is qualified and authorised for it will operate,
service, and repair the machine
•this personnel is instructed in all relevant issues of occupational
safety and environmental protection on a regular basis and is
familiar with the operating instructions and especially the safety
instructions contained therein
•all safety and warning instructions on the machine itself are not
removed and are legible

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1.2.4 Concrete security regulations and symbols used
In the following operating instructions, concrete security regulations are indicated in order to
point out the remaining risks which cannot be avoided when operating the machine. These
remaining risks include danger to
•Persons
•Product and machine
•Environment
The symbols used in the operating instructions are above all intended to point out the security
regulations!
This symbol indicates that especially danger to persons has to be
expected.
(Lethal danger, danger of injury)
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.
•Whenever there is a warning triangle with the caption “Danger” in front of a security
regulation, dangers to the machine, materials, and the environment are not excluded.
•Whenever there is a warning triangle with the caption “Warning” in front of a security
regulation, a danger to persons, however, must not be expected.
The symbol used in each case, however, cannot replace the text of the security instruction.
Thus, it is necessary to always read the text completely!
This symbol does not indicate security regulations, but provides
information for a better understanding of the machine’s operations.

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1.2.5 Security measures during normal operation
The machine may only be operated by trained and authorised
persons who are familiar with the operating instructions and are able
to work in accordance with it!
•Before starting the machine, check and make sure that
•only authorised personnel is staying in the operating area of the
machine
•Nobody can get hurt when the machine is started!
•Before every production start-up, the machine must be checked
for visible damage and it must be made sure that it is only
operated in faultless working condition! Any defects found must
be immediately reported to the supervisor!
Before every production start-up, all materials/objects that are not
necessary for production must be removed 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 maintenance and repairs
Inspection and maintenance periods laid down in the operating
instructions must be observed!
Observe maintenance and repair instructions in these operating
instructions, which refer to individual components!
Before performing maintenance and repair work, the access to the
operating area of the machine must be prohibited for unauthorised
personnel! Post or put up a sign, which indicates the maintenance, or
repair work!
Before performing maintenance and repair work, turn off the main
switch for the electric power supply and secure it with a padlock!. The
key to this padlock must be in the hands of the person who performs
the maintenance or repair work!
When exchanging heavy machine parts, use only suitable and
faultless load suspension devices and stopping devices!

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1.2.7 Work on the electrical equipment
Repair work on the electrical equipment of the machine may only be
performed by a trained electrician!
Electrical equipment must be checked on a regular basis!
Loose connections must be fixed again!
Exchange damaged lines/cables immediately!
Always keep the switch cabinet closed! Access is only allowed to
authorised personnel with keys/tools!
Never wash down switch cabinets and other housings of electrical
equipment with a water hose for cleaning!
1.2.8 Work on pneumatic equipment
Maintenance and repair work on pneumatic equipment may only be
performed by specially trained personnel!
Before starting maintenance and repair work, depressurise the
pneumatic equipment of the machine!
By way of precautionary maintenance, exchange hose pipes on a
regular basis, 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
•make sure that removed coverings are re-installed
After termination of maintenance and repair work and before re-
starting the production, make sure that
•all materials, tools, and other equipment required for maintenance
and repair work are removed from the operating area of the plant
•all safety devices of the plant function in a faultless manner!
1.2.9 Observe environmental regulations
During any and all work on and with the machine, the statutory duties
concerning prevention of waste and the proper waste
disposal/recycling regulations must be observed.
Especially in the case of installation, repair and maintenance work,
substances which are hazardous for the water, such as detergents
containing dissolvents, may not pollute the soil or get into the sewage
system!
These substances must be stored, transported, collected, and
disposed of in appropriate containers!

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2. Description
CAUTION! - The machine is connected to mains. Only authorised
personnel may open the cover. Operation without this cover is not
allowed.
This chapter explains the structure and the function of the labeller. The expressions used are
explained here.
2.1 Mechanics
The machine is available in a right- or a left-hand version. The expression right or left is related
to the direction of product transport. In the following, a right hand machine is explained. For the
left-hand version all explanations have to be mirrored. The dispensing mechanics of the
machine are shown below.
The label material is unwound from roller (003). The maximum diameter of the label roll is 300
mm. The maximum width is 100 mm. The material roll is guided by two removable plate’s (002).
The guide plate in front has to be pressed against the label roll. Behind the cap (004) of unwind
mandrel (003) an adjustment screw for the brake is located. The unwind brake avoids after run
of the label roll when the label drive stops.
Note: For labels longer than 100 mm and in "side labelling applications" it is
recommended to use the optional available kit dancer arm controlled unwind brake.
This device avoids uncontrolled after run of label material. The brake should not be
fixed too tight, otherwise the motor may stall or the material web gets broken.
The dancer arm (011) keeps the material tight and the acceleration forces low. The deviator
roller (008) makes sure that the material is guided correctly. The material is guided to the
dispensing edge via the deviator roller (009).
The brush (006) keeps the material tight without disturbing the movement. At the dispensing
edge (010) the label sensor (007) is mounted. The label sensor detects the gaps between
labels. The label sensor comprises of a light source and a light receiver. The sensitivity can be
adjusted by the operators panel.

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Figure 1 Dispensing mechanics
At the dispensing edge (010) the label is separated from the backing paper. By means of a soft
(005) roller the label is applied on to the product.
Roller (012) makes sure that the material is always guided properly around the dispensing
edge. Drive roller (001) keeps the transport speed of the material constant.
Deviator rollers (012) guide the backing material around the drive roller (001). The pressure
mechanics (013) press the backing paper against the drive roller (001).
With the handle (015) you may open and close the pressure mechanics (013) . When inserting
the material the pressure roller has to be opened.

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Dispensing is only possible when the handle (015) is in the closed position. Via the deviator
roller (016) the backing paper is guided to the rewind mandrel (017). The cone between the 4
pins can be pulled out to allow the reward backing paper to be removed.
Except for the drive roller (001) and the material brush (006) the labeller has no wearing parts.
The operator panel (019) is described in the next chapter.
A threading diagram is affixed to the front of the machine, which shows how the label material
should be threaded through the machine.
Screw (014) secures the position of the pressure roller (013) in a lateral direction. In order to
achieve a reliable run of the label web position, adjust the roller to the centre of the label web.
2.2 Operator panel
The operator panel (Figure 2) of the 230 is shown below, it has a 4 digit LED display and 4
membrane keys.
Figure 2 Operator panel
The 4 membrane keys have following functions:
FEED: By pressing this key one label will be dispensed. When the machine
displays INIT pressing this key will start initialisation of the machine. 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 label parameters "CONT" and "LPIT".

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PRIOR: This key moves up the menu (prior function) or increases the value of a
parameter. If the up arrow key is pressed and held as the machine is turned on
the product menu is selected.
NEXT: This key moves down the menu (next function) or decreases the value of
a parameter. If the down arrow key is pressed and held as the machine is turned
on the standard menu is selected.
ENTER: This key is used to enter or exit a menu point or to cancel a warning or
error message.
When the keys have different meanings, it will be explained in the relevant menu description.

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2.3 Plug board
The plug board is shown in Figure 3. Beside the mains switch and the mains cable socket there
are some more holes for optional functions. 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 strongly recommended to do this by means of the
optional available SUB-D connectors. This ensures best EMI stability of the machine.
CAUTION! - The fuse holder setting you have to select according to your local
main voltage (100, 120, 200 or 230 V). You carry this out by taking off the fuse
holder and position the fuse holder insert accordingly.
Figure 3 Plug board
2.4 Electronic
As standard the complete electronic is integrated in the machine. For special requirements
(water protection e.g.) a machine version the electronic is housed in a separate cabinet is
available.
Product sensor
APSF-Sensor
Applicator
PLC control

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Operators Manual
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3. Preparing the machine
In this chapter you will learn how to install and adjust the labeller. After this step has been
completed you will be ready to learn how the labeller's parameters can be adjusted to suit your
particular production requirements.
1.1 Installation
1.1.1 Unpacking of the unit
•For removing the unit off the box, don’t hold the machine on the dispensing edge to prevent
disadjustment off the machine.
•For mounting the machine, a complete system of holding tools is available. Ask your
representative.
•Take care that the machine is safe and stable mounted.
•There are rotating parts on the machine. Do the necessary actions to prevent that anybody
can be caught from these parts.
1.1.2 Connection of the machine
Before connecting the machine to the mains, check the correct setting of the line voltage. For
the connection of sensor, applicators e.g. see the chapter connections. Fix all cables to prevent
accidents and damaging of cables. Have also a look to the EMI chapter for proper machine
operation.
For checking of correct operation of sensors, applicators use the check functions SCHK, I_CH
and O_CH.
1.1.3 General setting
Normally the setting is done, but before operation check and note the general dispenser
configuration: dispenser direction, machine type, applicator mode, and APSF function.
1.2 Prepare dispensing
1.2.1 Insert material
Insert your label material in the machine to follow the instructions in the chapter Operation /
Threading.

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Release 12/07 Page 18 Preparing the machine
1.2.2 Define label data
For correct dispenser operation, you have to tell the machine the length of the label and adjust
the label sensor. Normally this is done automatically. For this follow the instructions in chapter
Operation / Initialise material.
There are some reasons the automatic initialisation is not possible:
1. Using another then the standard optical label sensor
2. Label material with a low contrast ratio between label and backing paper
3. Labels with holes inside the label
In this case, you have to set one or both of the parameter manually.
Activate the extended standard menu to do the settings by:
yPressing both keys NEXT and PRIOR simultaneously
Display: CODE
yPassword CODE entering:
1 time pressing the key PRIOR FUNCTION
2 times pressing the key NEXT FUNCTION
3 times pressing the key ENTER
Display: LPIT
ySetting the label length
Enter the LPIT function by pressing ENTER. Measure the distance from one label edge to
the edge of the next label. Enter the value in mm by using the function keys. Press ENTER
to leave the function. See also the information below.
yChange the setting of the label sensor
If another label sensor then the Wenglor type will be used, call the CONT function and set
the value to any manual value (e.g. M006.).
If the contrast ratio is low, follow the instructions to adjust manually contrast.
yTo store the setting permanent leaves the menu with the QUIT function. If you power off the
machine without quit all modification are lost.
yBy pressing the key FEED one label can be dispensed if you are in the parameter selection.