Novexx Solutions ALS/XLS 204 User manual

Edition 9 - 5/2019 - Translation of original version
SERVICE / INSTALLATION
MANUAL
ALS/XLS 20x/256/272
Labeler

Service Manual ALS 20x/256/272
05/2019 3Contents
Contents
Please observe the following -9
General information -9
Validity and applicability of this manual -9
Conventions and information -10
Notes on installation and repair work -11
Safety instructions -15
Information and qualifications -15
Machine operating safety -16
Safe operation -17
Technical Data -19
Technical Data -19
Characteristics -19
Labels -19
Label sensor -20
Power supply -20
Electronics -21
Interfaces -21
Internal Interfaces -22
Status messages, test functions, 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 connecting the machine -36
Transport -36
Unpacking -36
Setting up -37
Attaching the dispensing edge -41
Connecting to the mains power supply -43
Connecting the sensors -46
Photoelectric label sensor -46
Alternative label sensor -51
Changing light/dark switching at the product sensor or the alternative label sensor -58

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Photoelectric product sensor -59
Photoelectric roll diameter sensor -60
Rotary encoder -64
Installing Options -66
Connecting / mounting the external operator panel -66
Mounting a splice table -68
Mounting/connecting the signal beacon -69
Adjustable dispensing edge holder -70
Rotatable dispensing edge holder -71
Narrow label spring kit (ALS/XLS 20x and ALS/XLS 256) -74
Decommissioning, Dismantling, Disposal -76
Take the machine out of operation -76
Dismantling the machine -76
Machine disposal -77
Functions -78
Function menu -78
Overview -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. -100
Submenu >OPERATION DATA -101
Submenu >POWERSUPPLYDATA -101
Submenu >CPU BOARD DATA -102
Submenu >DISPLAY DATA -102
Submenu > PERIPHERAL DATA -103
Submenu >MEMORY DATA -103
Operation -104
Automatic dispensing speed adjustment -104
Principle of operation -104
Mounting the rotary encoder -105
Entering the rotary encoder resolution -106
Entering the diameter of the measuring wheel -106

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Entering the rotary encoder type -106
Example: Entering the values for the recommended rotary encoder -107
Calibrating the belt speed -107
Calculation scheme for the automatic dispensing speed adjustment -108
Tandem Operation -111
Overview -111
Master operating modes -111
Prerequisites -112
Setting up tandem operation -114
Applicator Operation -121
Function -121
System requirements -121
Assembly and operation -121
Enhanced Functions -122
Access via a Web/FTP server -122
Web server -122
FTP server -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
Immediately executable commands -143
Not immediately executable commands -146
Forced bootloader start -150
Gen. 1 -150
Gen. 2 -151
Diagnose Dump -152
Storing diagnosis data -152
Reading out via serial interface -152
Storing on memory medium -155
Electronics Description -156
Wiring Diagrams -156
„Gen. 1“-Electronics -156
„Gen. 2“-Electronics -159
Block diagram -162

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Electronics Components -163
ALS/XLS 20x -163
ALS/XLS 256 -164
ALS/XLS 272 -165
Circuit boards -166
CPU board (Gen. 1) -166
CPU board (Gen. 2) -172
Motor driver board -179
Operator panel board -181
Applicator Interface -184
Power supplies / Transformer -191
Power supply ALS/XLS 20x -191
Transformer ALS/XLS 20x -193
Power supply ALS/XLS 256/272 -193
Signal Interface -195
General notes -195
Circuit diagrams for signal inputs -196
Circuit diagram for signal outputs -197
Signals for applicator connection -197
Applicator 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
Circuit diagrams for signal outputs -219
Power outputs -220
Pin assignment for applicator connection -221
Pin assignment for machine status connection -224
Pin assignment for product sensor connection -226
Signal-LEDs -227
Signal wave forms -227
Fault description -228
Types of status messages -228
Error messages -228
Warnings -228
Setting back a warning -228

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General software errors -229
Machine fails to start -229
Reference of status messages -230
List of warnings -230
List of error messages -231
Repair -242
Tests -242
Sensor test -242
Power Supply ALS/XLS 256/272 -245
Initial state -245
Power supply functions -245
Checking output voltages -246
Troubleshooting -249
Checking the power supply -251
Opening the casing -252
Removing the dust/splash guard (ALS/XLS 20x) -252
Opening the casing at machines held in place by side plate or base 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 -302
Additional helpful information -302
Installing a „Generic“ printer on a Windows 7 host PC for the purpose of firmware upload
-302
Settings -305
Setting the capacitive (Leuze) sensor -305
Calculation sheet for performance diagrams -306
Using the calculation sheet -306
Inputs -306
Outputs -307
Diagrams of performance data -307

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Service Manual ALS/XLS 20x/256/272
05/2019 | 04 9
Please observe the following
GENERAL INFORMATION
Validity and applicability of this manual
Contents
The present service manual refers exclusively to the labelers:
– ALS 204, ALS 206, ALS 209, ALS 256, ALS 272
– XLS 204, XLS 206, XLS 209, XLS 256, XLS 272
The manual is to be referred to for correct installation, set-up, adjustment and repair of the labelers.
The complete operating manual for the respective labeler consists of the following parts:
Technical State
Technical state: 5/2019
Software versions:
– Firmware: 2.76
– Applicator Interface: 1.44
Liability
NOVEXX Solutions assumes no liability for damages resulting from improper adjustments 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 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
Manual Target group Medium Availability
User manual Operating personnel Printed Comes with machine
Installation manual Service personnel User Docu-CD
Service manual Service Docu-CD NOVEXX Solutions Partner
Portal: www.novexx.com
Spare parts catalogue

Service Manual ALS/XLS 20x/256/272
05/2019 | 04 10
Manufacturer
Novexx Solutions GmbH
Ohmstraße 3
D - 85386 Eching
Phone: [phone]
FAX: [phone]
www.novexx.com
Conventions and information
Explanation of symbols
In order to facilitate legibility and an overview, the various types of information used herein are cat-
egorised and identified with certain symbols.
Sentences that are introduced by an arrow contain procedural 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 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 brack-
ets. Capital letters following an illustration number, e.g. [12A], refer to the corresponding position
indicated in the illustration.
WARNING!
A warning notice indicates risks which could result in death or serious injury of the personnel!
The notice contains safety instructions on how to safeguard possibly affected 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 dam-
age or injury.
The instructions must be followed.