Novexx Solutions ALX 73 Series User manual

04/13 Rev. 5.08-02 SERVICE MANUAL
ALX 73x
Installation/Deinstallation
Defining the operating position ..................... 2
Space requirement .................................... 2
Admissible operation positions .................. 2
Top labelling .............................................. 3
Side labelling ............................................. 5
Unpacking and assembling the machine ...... 7
Transportation ........................................... 7
Unpacking the machine ............................. 7
Mounting the machine on a support stand 8
Mounting the unwinder ............................ 13
Mounting the holding plate ...................... 15
Configuring the dispensing edge holder .. 16
Mounting the dispensing edge holder ..... 19
Mounting the dispensing edge ................ 20
Mounting the dancer arm unit ................. 21
Mounting an additional deflection roller ... 21
Connecting remote operation panels .......... 22
Important notes ....................................... 22
Connecting .............................................. 22
Wall mounting ......................................... 22
Connecting to the mains power supply ....... 23
Producing the power cable ...................... 24
Connecting the sensors .............................. 25
Label sensor ............................................ 25
Alternative label sensor ........................... 27
Position sensor for linear dancer arm ..... 31
Product sensor ........................................ 32
Changing light/dark switching at the product
sensor or the alternative label sensor ..... 33
External OD sensor ................................. 34
Internal OD sensors ................................ 37
Rotary encoder ........................................ 38
Installing APSF ............................................40
Principle of operation ...............................40
Mounting the rotary encoder ....................41
Entering the rotary encoder resolution .....42
Entering the diameter of the measuring
wheel .......................................................42
Entering the rotary encoder type .............43
Input of encoder data ...............................43
Calibrating the belt speed ........................44
Calculation scheme for the automatic
dispensing speed adjustment ..................44
Mounting of options .....................................47
Applicators ...............................................47
Adjustable dispensing edge holders ........48
Dancer arm unit with double roller ...........50
Decommissioning, Dismantling, Disposal ...51
Take the machine out of operation ..........51
Dismantling the machine .........................51
Machine disposal .....................................52
Appendix .....................................................53
Length chart for adjustable dispensing
edge holder ..............................................53
Diagram for determining the length of the
dispensing edge holder (with double
deflection roller) .......................................54

04/13 Rev. 5.08-01 SERVICE MANUAL Defining the operating position
ALX 73x
2
Defining the operating
position
Space requirement
For machine dimensions read topic section Technical
Data > „Entire unit“ > „Dimensions“.
On the machine side facing the operator must be left at
least 1 m free space for loading and changing of sup-
plies.
On the connector-side of the machine and at the sides
must be left at lest 0.5 m free space due to:
• Optimal air exchange at the ventilation openings
[1A, B]
• Accessibility of the mains switch
Admissible operation positions
The ALX 73x may only be used for labelling from the fol-
lowing directions:
• Top labelling,
see chapter Top labelling on page 3
• Side labelling,
see chapter Side labelling on page 5
The machine should be fixed at a mounting point, which
is recommended for the applied configuration (see
(Tab. 1) and the following chapters).
For recommended fixtures read chapter Mounting the
machine on a support stand on page 8.
Sign Meaning
1 Recommended
2O.k.
3 Not recommended
(X) Mounting point on the rear side
[Tab. 1] Meaning of the signs used in the pictures.
[1] Ventilation openings (A, B) at ALX 73x.
A
B

04/13 Rev. 5.08-01 SERVICE MANUAL Defining the operating position
ALX 73x
3
Top labelling
Horizontal operating position
[4] Horizontal position for top labelling with one unwinder on top.
[2] Horizontal position for top labelling with two unwinders.
[3] Horizontal position for top labelling with one unwinder left.
1
(X)
2
1
1
2
(X)
1
3(X)
2

04/13 Rev. 5.08-01 SERVICE MANUAL Defining the operating position
ALX 73x
4
Vertical operating position
[6] Vertical operating position for top labelling with one top mounted
unwinder.
[5] Vertical operating position for top labelling with one side
mounted unwinder.
1
(X)
2
1
1
(X)
2
1

04/13 Rev. 5.08-01 SERVICE MANUAL Defining the operating position
ALX 73x
5
Side labelling
Horizontal operating position
[9] Horizontal operating position for side labelling with one top
mounted unwinder.
[7] Horizontal operating position for side labelling with two
unwinders.
[8] Horizontal operating position for side labelling with one side
mounted unwinder.
2
(X)
1
2
2
1
(X)
2
3(X)
1

04/13 Rev. 5.08-01 SERVICE MANUAL Defining the operating position
ALX 73x
6
Vertical operating position
[11] Vertical operating position for side labelling with one top mount-
ed unwinder.
[10] Vertical operating position for side labelling with one side
mounted unwinder.
1
(X)
2
3
1
(X)
2
1

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
7
Unpacking and assembling
the machine
Transportation
Unpacking the machine
Lift the machine out of the packaging with at least 2
persons.
To do so, hold the machine by its casing.
As a lashing point for the crane, screw in an M10
[12A] eye bolt in a threaded hole at one of the flanges.
After unpacking, check the machine for visible ship-
ment damage.
WARNING!
Acute risk of injury and long-term bodily inju-
ry from working with heavy loads!
Lift or carry the machine with a minimum
or 2 persons. If possible, use a crane or
other lifting device.
VORSICHT!
To avoid damaging the machine during
transporting:
Only use the original packaging for
machine transportation.
Keep the original packaging for later
transportation.
CAUTION!
To avoid damaging the machine during un-
packing:
Never hold the machine by the deflection
rollers, dancer arm, rewinder or unwinder.
[12] Attaching an eye bolt.
A

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
8
Mounting the machine on a support
stand
Mounting options
The ALX 73x can be mounted in two ways:
• At the machine rear side [13], see chapter Rear
side mounting on page 9.
• At one of the flanges at the machines outer side
[14], see chapter Mounting at the machines outer
side on page 11.
Recommended mounting points for the different op-
eration positions see chapter Admissible operation
positions on page 2.
WARNING!
Risk of injury from a tipping over support
stand.
When installing the machine on a support
stand, make sure that it can not tip over.
Fix the support stand onto the ground.
[13] Rear side mounting.
[14] Bottom mounting.

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
9
Rear side mounting
Prerequisites:
•Support stand with a tube end providing the follow-
ing measures:
– Outer-Ø: 60 mm
– Wall thickness: minimum 5 mm
•Adjustable head joint [19] (article number A9773)
[19] Adjustable head joint in state of delivery.
Tools:
6/10/17 mm allen keys
Assembly:
1. Remove the cover plug [15A] from the lange on the
machines rear side.
2. Locate the two cylinder pins [14B] in the holes in the
machine side bracket [14C].
3. Screw the machine side bracket onto the flange on
the rear side of the machine using the provided
screw 1[14D].
The two cylinder pins must locate into the holes
in the flange.
Tightening torque: 350 Nm
4. Turn the adjustment screw [16B] and both clamp
screws [16A] some rotations out.
5. Insert the support stand side bracket [17A] and
push in the axle [17B] flush.
6. Tighten the 2 clamp screws [17C].
Tightening torque: 70 Nm
7. Loosen the clamp screw [17D].
8. Push the machine with the head joint onto the sup-
port stand tube [18A] and thighten the clamp screw
[18B].
Tightening torque: 70 Nm
Continued overleaf.
1) DIN EN ISO 4762 M20x40 (8.8)
[15] Mounting the machine side bracket.
[16] Machine side bracket mounted.
[17] Mounting the support stand side bracket.
[18] Mounting to the support stand.
A
B
C
D
A
A
B
A
B
C
D
A
B

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
10
9. Incline the machine to the required angle by turning
the adjustment screw [20A].
Turn in = Inclination upwards
Turn out = Inclination downwards
10. Tighten the 2 clamp screws [21A].
Tightening torque: 70 Nm
[20] Setting the declination.
[21] Tightening the clamp screw (A).
A
+4°
-4°
A

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
11
Mounting at the machines outer side
Prerequisites:
•Support stand with a tube end providing the follow-
ing measures:
– Outer-Ø: 60 mm
– Wall thickness: minimum 5 mm
•Flange plate [22A] (article number A7622, including
bolts and washers)
Tools:
8/10 mm allen keys
Assembly:
1. Screw the flange plate [22A] to an appropriate
flange at the machine.
Note the recommended mounting points, see
chapter Admissible operation positions on
page 2.
Use the 4 bolts shipped with the flange (DIN EN
ISO 4762 M10x25 A2).
Tightening torque: 45 Nm
2. Lift the machine and push the clamping part of the
flange plate onto the support stand tube [22B].
Tighten the clamp screw.
Lift the machine with a minimum of 2 persons or
with a crane; let a 3rd person tighten the screw.
Tightening torque: 70 Nm
[22] Mounting the flange plate to an ALX 73x.
A
B

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
12
Mounting with adjustable head joint at the
machines outer side
To attach the machine inclinable at its outer side, the
flange plate can be combined with the adjustable head
joint.
Prerequisites:
•Support stand [23D] with a tube end providing the
following measures:
– Tube outer-Ø: 60 mm
– Wall thickness: minimum 5 mm
•Flange plate [23A] (article number A7622, including
bolts and washers)
•Adapter tube [23B] (article number A9951)
•Adjustable head joint [23C] (Artikelnummer A9773)
Tools:
6/8/10/17 mm allen keys
Assembly:
1. Screw the flange plate [23A] to an appropriate
flange at the machine.
Note the recommended mounting points, see
chapter Admissible operation positions on
page 2.
Use the 4 bolts shipped with the flange (DIN EN
ISO 4762 M10x25 A2).
Tightening torque: 45 Nm
2. Push the adapter tube [23B] into the clamping of
the flange plate. Tighten the clamp screw.
Tightening torque: 70 Nm
3. Mount the adjustable head joint [23C] to the adapt-
er tube. How to? - see chapter Rear side
mounting on page 9.
4. Lift the machine and push the clamping part of the
flange plate onto the support stand tube [23D].
Tighten the clamp screw.
Lift the machine with a minimum of 2 persons or
with a crane; let a 3rd person tighten the screw.
Tightening torque: 70 Nm
[23] Mounting with flange plate (A) and adjustable head joint (C).
[24] Mounting with flange plate and adjustable head joint.
AB
C
D

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
13
Mounting the unwinder
Mounting notes
•RH unwinder: For mounting the unwinder on top
right or at the right side, a RH model must be used,
see rating plate [25 circle].
•LH unwinder: For mounting the unwinder on top left
or at the left side, a LH model must be used, see
rating plate [25 circle].
Tool: 8 mm allen key
Mounting the unwinder holder to the housing
1. Define the unwinder mounting position, see chapter
Admissible operation positions on page 2.
2. Screw the unwinder holder [26A] with 4 screws to
the frame of the ALX 73x [26].
Aligning the unwinder: the edge of the unwinder
foot [26A] must abut on the edge of the flange
[26B].
Use the 4 screws shipped with the flange (DIN
EN ISO 4762 M10x25 A2).
Tightening torque: 45 Nm
Mounting the deflection roller to the unwinder
holder
Unwinder holder is mounted on top:
Mount the deflection roller as pictured [27].
Unwinder holder is mounted at a side:
Umlenkrolle wie abgebildet befestigen [28].
The roller axle is being fixed with two set screws
[28A].
The 2 studs [28B] must abut on the unwinder holder
as pictured.
[28] Mounting the deflection roller (side mounted unwinder).
[25] Rating plate position at the unwinder dancer arm (circle).
[26] Aligning the unwinder to the flange.
[27] Mounting the deflection roller (top mounted unwinder).
A
B
A
B
B

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
14
Mounting the unwinder to the unwinder holder
1. Push the unwinder onto the unwinder holder.
Abwickler [31A] auf den Abwicklerhalter [31B]
stecken.
Top mounting: The stud at the unwinder holder
must engage in the centre hole [31C][29] at the un-
winder.
Side mounting: The stud at the unwinder holder
must engage in the outer hole [31C][30] at the un-
winder.
2. Fix the unwinder with screw [31E].
Tightening torque: 45 Nm.
3. Connect the OD sensors.
See chap. Internal OD sensors on page 37.
[31] Mounting the unwinders to the unwinder holders.
[29] Engagement position (circle) of the stud if mounted on top.
[30] Engagement position (circle) of the stud if mounted at a side.
LH RH
LH RH
A
A
B
B
C
D
E
E

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
15
Mounting the holding plate
Tool
8 mm hex socket screwdriver
Mounting
Attach the dispensing edge holding plate [32A] with
4 screws to the frontal housing flange.
The 2 studs [32B] in the holding plate must rest on
the flange edge [32C].
Use the shipped screws (DIN EN ISO 4762 M10x20
A2).
[32] Mounting the dispensing edge holding plate (A).
A
B
C

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
16
Configuring the dispensing edge
holder
An ALX 73x with standard dispensing edge holder and
fixed L-shape dispensing edge can print labels up to a
length of 225 mm without having to modify the length of
the dispensing edge holder.
Longer labels (up to 440 mm) can be processed, if the
length of the dispensing edge holder is checked and is,
under certain circumstances, modified.
For this purpose can be applied optional length-
adjustable dispensing edge holders, see Adjustable
dispensing edge holders on page 48.
By means of the diagram [34], the required dispensing
edge holder length can be determined dependent on
the label length. The coloured areas show the ranges
of admissible dispensing edge holder lengths. The la-
bel length plots against the x-axis, the dispensing edge
distance plots against the y-axis left and the dispensing
edge holder rod lenths plot against the y-axis right.
Application conditions for the diagram:
• The dispensing edge holder is not swivelled ahead
(that is, the position of the dispensing edge holder
must match fig. [33])
• The linear dancer lever is equipped with a single
deflection roller..
Application of the optional double deflection roller:
see Diagram for determining the length of the dispen-
sing edge holder (with double deflection roller) on
page 54.
Continued overleaf.
[33] Measures for the dispensing edge holder rods (B) and for the
dispensing edge distance (A).
Dispensing edge holder rod length
Distance dispensing edge
B
A

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
17
[34] Diagram for finding out the optimum length of the dispensing
edge holder (linear dancer lever with single deflection roller).
Reading example:
Starting with a label length 1of 330 mm [34A], the dia-
gram shows a length range for the rods of 145 mm
[34B] to 255 mm [34C] (dotted lines). If one chooses a
point in the middle of the range, this results in approx.
200 mm [34D].
All points in the coloured areas, including the points
on the border lines are admissible.
The related measure for the dispensing edge dis-
tance can be read on the left y-axis.
1) including the gap
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A
B
C
D

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
ALX 73x
18
An additional length area results, if the vertical line
is elongated until it cuts the second coloured area. The
examle shows here an admissible rod lengthof 475 to
511 mm (dashed lines).
The black dashed line marks the length of the
standard dispensing edge holder. The diagram shows,
that the example labels with 330 mm length can also be
processed with this dispensing edge holder. Not proc-
essed with the standard holder can be labels with one
of the following lengths:
•270-320mm
•>360mm

04/13 Rev. 5.08-02 SERVICE MANUAL Unpacking and assembling the machine
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Mounting the dispensing edge holder
The dispensing edge holder is required for mounting
L-shape dispensing edges.
Both, the dispensing edge holder [35A] and the mount-
ing flange [35B] on the holding plate have two concen-
tric rings of holes on the connecting surfaces. Two pins
[35C] that fit into these holes are provided with the dis-
pensing edge holder. To secure the dispensing edge
holder so it cannot swivel, the pins are located in dia-
metrically opposite holes. By replacing the pins in adja-
cent holes, the mounting angle of the dispensing edge
holder can be adjusted in 15° increments.
Tool
8 mm hex socket screwdriver
Assembly:
1. Locate the pins [36C] in diametrically opposite
holes.
2. Fit the dispensing edge holder onto the pins at the
required angle.
Choose either inner or outer circle of holes, de-
pendent on the required angle.
3. Fix the dispensing edge holder in place with screw
[35D].
[35] Mounting the dispensing edge holder (A).
A
B
C
D

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ALX 73x
20
Mounting the dispensing edge
Mounting a L-shape dispensing edge
Prerequisite: Dispensing edge holder is mounted.
Tool
Hex socket screwdriver, 8 mm
Mounting:
1. Fit the dispensing edge [36A] as pictured.
Position the dispensing edge so that the inner
side plate touches the edge of the label web (mate-
rial zero line).
2. Connect the label sensor.
See chap. Label sensor on page 25.
The following optional available dispensing edges
are attached in the same way:
• Swivelling dispensing edge
• Spring-loaded dispensing edge
• Pneumatic dispensing edge
Mounting a V-shape dispensing edge
Tool
• Hex socket screwdriver, 2.5 mm
• Socket spanner, SW 16
Mounting:
1. Fit the V-shape dispensing edge [36A] in the re-
quired tilt angle as pictured.
The maximum length adjustment range is
reached with a tilt angle of 6.5° [37A].
2. Install the additional deflection roller, see Mounting
an additional deflection roller on page 21.
3. Connect the label sensor.
See chap. Label sensor on page 25.
Length adjustment:
1. Loosen the 4 set screws [38A] in the cross-beam.
2. Shift the dispensing edge to the appropriate length.
Adjustment range at 6.5° tilt angle: 173 -
421 mm. See measure x in [38B].
3. Re-tighten the set screws.
[36] Mounting a fixed L-shape dispensing edge (A).
A
[37] Mounting a V-shape dispensing edge.
[38] Length adjustment of the V-shape dispensing edge.
6,5°
A
x
A
B