Novexx Solutions ALX 73 Series User manual

04/13 Rev. 5.08-02 USER MANUAL
ALX 73x
Startup and operation
Electrical connections ................................... 2
Connecting to the mains power supply ..... 2
Connecting sensors .................................. 3
Inserting label material .................................. 4
Inserting the label roll ................................ 4
Threading in the label web ........................ 5
Replacing a label roll ............................... 11
Inserting/replacing ribbon ............................ 12
Inserting ribbon ....................................... 12
Changing ribbon ...................................... 13
Mechanical settings .................................... 15
Adjusting the core diameter of the
unwinder .................................................. 15
Positioning the pressure roller ................. 15
Position the label sensor on the
dispensing edge ...................................... 16
Position the label sensor in the printer .... 16
Setting the ribbon tension ....................... 17
Setting the printhead pressure ................ 18
Setting the return force of the unwinder
dancer lever ............................................ 19
Setting the return force of the linear
dancer lever ............................................ 20
Switching the unit on and off .......................21
Switching the machine on/off ...................21
Setting and monitoring the dispenser ..........22
Settings in parameter menu .....................22
Monitoring functions .................................25
Setting and monitoring the printer ...............27
Settings in parameter menu .....................27
Monitoring functions .................................28
Printing ........................................................30
Creating print jobs ....................................30
Installing the printer driver .......................30
Transferring a print job .............................30
Using product profiles (dispenser) ...............32
What are product profiles? .......................32
Loading a product profile .........................32
Saving a product profile ...........................33
Deleting a product profile .........................34

2| Electrical connections User manual ALX 73x | file version 01 | 04/2013
STARTUP AND OPERATION
ALX
73x
Electrical connections
Connecting to the mains power
supply
The machine mains supply plug is delivered with the
machine, unattached.
The mains supply plug must only be connected
with the mains power connecting line by an
authorised specialist. The specialist must be
acquainted with the associated dangers.
For information about preparing the mains power
connecting line, see the Assembly/Service manual.
To plug in the mains power connecting line:
1. Ensure that the machine is switched off (mains
power switch [1A] in position "O").
2. Plug the mains power connecting line [1B] into the
machine.
3. Close the safety bracket [2].
To unplug the mains power connecting line:
1. Ensure that the machine is switched off (mains
power switch [1A] in position "O").
2. Open the safety bracket [1B].
3. Remove the mains power connecting line.
WARNING!
This unit operates at mains voltage! Contacting electrically live components can
cause lethal electrical shocks and burns.
The machine must only be connected to the mains power supply by an
authorised specialist. This person must be acquainted with the associated dangers.
Only operate the unit at the mains voltage given on the type plate.
Make certain the units is switched off before you plug in the mains power
connecting line.
The maximum permitted length of the mains power connecting line is 3 m.
[1] Mains power connecting line (B) plugged in.
[2] Safety bracket closed.
C
A
B

User manual ALX 73x | file version 01 | 04/2013 Electrical connections | 3
STARTUP AND OPERATION
ALX
73x
GB
Connecting sensors
Before switching on the machine, check to ensure all
required sensors are securely connected [3].
More extensive information about suitable
sensor types, pin assignment, etc. may be found
in the Assembly/Service manual.
Minimum required sensors
• Label sensor [3A]
(assembly location: dispensing edge)
• Product sensor [3B]
(assembly location: assembly line)
• Linear dancer lever sensor [3E][4]
Optional additional sensors
• Rotary encoder (for automatic speed adaptation)
[3C].
• Alternative label sensor [3D]
• Sensors for internal OD detection:
The sensors for OD detection are integrated into
the material dispenser and must be connected with
the optionally available cables.
– Dispenser 1: connections [3G+H]
– Dispenser 2: connections [3I+J]
WARNING!
This unit operates at mains voltage!
Contacting electrically live components can
cause lethal electrical shocks and burns.
The machine must only be connected
with other machines if they meet the
requirements of a SELV circuit (Safety
Extra-Low Voltage circuit) in accordance
with EN 60950.
[3] Connections for sensors:
ALabel sensor (dispenser)
BProduct sensor
C(Optional) rotary encoder
D(Optional) alternative label sensor
ELinear dancer lever sensor
FExternal RD sensor
GInternal roll diameter (OD) detection, unwinder 1
HInternal OD detection, unwinder 1
IInternal OD detection, unwinder 2
JInternal OD detection, unwinder 2
[4] Connect the sensor of the linear dancer lever with the cable
(A) included with delivery.
[5] Connections (A) for internal OD detection on the dispenser.
B
G
J
I
H
C
A
D
F
E
A
A

4| Inserting label material User manual ALX 73x | file version 05 | 04/2013
STARTUP AND OPERATION
ALX
73x
Inserting label material
Inserting the label roll
1. If necessary, adjust the diameter of the unwinding
mandrel to the core diameter of the material roll;
see section Adjusting the core diameter of the
unwinder on page 15.
2. Push the material roll [6A] onto the dispenser until
it stops.
3. Turn the knob [6B] clockwise until the label roll is
firmly seated.
For the remainder of the material flow, see sec-
tion Threading in the label web on page 5.
WARNING!
Danger of injury due to moving and rapidly
rotating parts!
Before inserting the label roll ensure that
the printer and dispenser are both in offline
mode.
Danger of injury caused by falling label roll.
Wear safety shoes.
[6] Inserting a material roll
B
A

User manual ALX 73x | file version 05 | 04/2013 Inserting label material | 5
STARTUP AND OPERATION
ALX
73x
GB
Threading in the label web
Threading diagrams
The following illustrations show the flow of material 1
through the ALX 73x in different installation positions
and designs with right-hand and left-hand versions.
[7] Flow of material with horizontal installation and one unwinder.
[8] Flow of material with horizontal installation and two unwinders.
1) Solid line: flow for material rolls with labels on the outside. Dotted
line: deviating flow for material rolls with labels on the inside.

6| Inserting label material User manual ALX 73x | file version 05 | 04/2013
STARTUP AND OPERATION
ALX
73x
[9] Flow of material with vertical installation and one unwinder.
[10] Flow of material with horizontal installation, one unwinder and
double roller at the dancer lever.

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STARTUP AND OPERATION
ALX
73x
GB
[11] Flow of material with horizontal installation, one unwinder and
V-shape dispensing edge.

8| Inserting label material User manual ALX 73x | file version 05 | 04/2013
STARTUP AND OPERATION
ALX
73x
Threading the label web into the printer
1. Open the printer cover [12].
Hold the cover on the bottom right [12A].
2. Adjust the material guide to the width of the label
web. To do this, release the thumb screw [13A] on
the outer material guide [13B], push the material
guide up to the edge of the label material and screw
in the thumb screw again until it is tight.
The label material should move easily between
the guides.
3. Push the label material through the material guide
and up under the pressure roller.
4. Detach the pressure roller. To do this, rotate the
green lever [13C] in the direction of the arrow.
5. Push the material end under the printhead.
6. 2,5 Unroll the 2.5-m label web and remove the la-
bels from it.
7. Close the green lever [14].
Threading in the label web on the linear dancer
lever
Place the label web around the dancer lever; see
section Threading diagrams on page 5.
[12] Open the printer cover.
[13] Adjust the material guide (B) for the width of the material.
[14] Shut the lever for the pressure roller.
A
A
C
B

User manual ALX 73x | file version 05 | 04/2013 Inserting label material | 9
STARTUP AND OPERATION
ALX
73x
GB
Thread in the label web on the dispensing
edge
Fixed [15] and swivelling L-shape dispensing edges:
1. Guide the backing paper around the first deflection
roller [15A] and through the slot in the sensor [15B].
2. Guide the backing paper under the pressure roller
[15C] to the dispensing plate [15D].
3. Guide the backing paper around the dispensing
plate to the second deflection roller [15E].
4. Set the tension of the backing paper so that the
dancer lever is in the centre or at the upper limit.
Spring-loaded [16] and pneumatic [17] L-shaped dis-
pensing edges:
Guide the backing paper between the two thin guide
rollers at the articulation point [16A] [17A] as well.
[17] Flow of the label web on the pneumatic dispensing edge (option-
al).
[15] Flow of the label web in the area of the dispensing edge.
A1. Deflection roller
BLabel sensor
CPressure roller
DDispensing plate
E2. Deflection roller
[16] Flow of the label web on the spring-loaded dispensing edge
(optional).
C
A
B
D
E
A
A
A
A

10 | Inserting label material User manual ALX 73x | file version 05 | 04/2013
STARTUP AND OPERATION
ALX
73x
Thread in the label web on the drive roller
1. Open the pressure roller. To do this turn the lever
[18A] clockwise.
2. Position the backing paper around the deflection
roller [18B] and drive roller [18C].
3. Close the pressure roller. To do this turn the
lever [18A] anticlockwise until you feel it snap into
place.
Thread the label web onto the rewinder
1. Guide the backing paper around the deflection roll-
er and dancer lever [19].
2. Clamp the backing paper in place as shown on the
rewinder [20].
When the machine is switched off:
Turn the rewinder clockwise until the backing paper
is taut [21].
When the machine is switched on:
1. Ensure that the printer and dispenser are both in
"Offline" mode.
2. Press the dancer lever against the upper stop and
hold it there for longer than 2 seconds.
The following error message appears on the dis-
penser´s display:
Now, the rewinder can be turned manually.
3. Turn the rewinder one turn.
4. Press the -key to acknowledge the error mes-
sage.
Status num: 5143
Rewinder stop
[18] Open the pressure roller.
[19] Guide the backing paper around the dancer lever and deflection
roller.
[20] Clamp the backing paper firmly in place on the rewinder.
A
B
B
C

User manual ALX 73x | file version 05 | 04/2013 Inserting label material | 11
STARTUP AND OPERATION
ALX
73x
GB
Replacing a label roll
Detecting end of roll
To keep downtimes during production as short as pos-
sible, the roll should be changed as quickly as possible.
Threading the label material through the entire machine
is relatively time consuming. Threading in can be avoid-
ed by connecting the beginning of the new material roll
to the end of the old material roll (= splicing). This
means that the material end must be detected before it
is too late.
Various functions are provided for detecting the materi-
al end; see section Material end / roll diameter on
page 25.
Remove wound carrier material
1. Press in the unlocking button [22B].
The rewider's spreading mechanism is loosened.
2. Remove wound backing paper.
Insert a new label roll
1. Insert a label roll; see section Inserting the label
roll on page 4.
2. Connect the material beginning of the new roll [23A]
with the material beginning of the used material
[23B] (adhesive tape).
3. Press the Enter key to confirm the error message.
4. Tighten the label web. To do this press the dispens-
er dancer lever down and turn the dispenser back-
wards.
5. Feed the splicing point forward until it has passed
the dispensing edge. To do so, press the feed key
at the printer and afterwards the key at the dis-
penser.
Printer: Slightly pull the label web out of the
printer while feeding it, otherwise the web could
jam.
If labels are missing, the gaps must also be fed
past the dispensing edge.
6. Printer: Press the Feed key to continue the print
job.
[22] Backing paper rewinder.
AWound backing paper
BUnlocking button
[23] Connect beginning (A) and end (B) of material.
AB
A
B

12 | Inserting/replacing ribbon User manual ALX 73x | file version 00 | 04/2013
STARTUP AND OPERATION
ALX
73x
Inserting/replacing ribbon
Inserting ribbon
1. Open the cover.
2. If necessary remove used ribbon.
3. Place a new ribbon roll on the ribbon unwinding
mandrel [25A]. Insert an empty take-up roll onto the
ribbon rewinding mandrel [25B].
4. Insert the end of the ribbon below the ribbon deflec-
tor [25C] and thread through to side of printhead
[25D].
5. Pull the ribbon below the printhead from the side.
Next, unwind some ribbon and smoothen it out.
6. Pull the ribbon upwards and, as shown [24], pass it
around the ribbon roller [25E], ribbon deflection roll-
er and strain relief [25F].
7. Fasten the end of the ribbon to the take-up roll man-
drel [26].
WARNING!
Rotating parts can entrap objects and
body parts and draw them in!
Never wear loose long hair, loose
jewellery, long sleeves or similar items
when working with the machine.
Always close the printer cover before
printing.
The printhead can become hot during ope-
ration!
Be careful whenever touching the prin-
ter.
CAUTION!
If the diameter of the wound ribbon becomes
too large, this will impair the printer opera-
tion.
Always remove the used ribbon before
inserting a new ribbon roll.
[24] Threading diagram for ribbon.
[25] Printer with cover open.
ARibbon unwinding mandrel
BRibbon winding mandrel
CDeflector
DPrinthead
ERibbon roller
FStrain relief
[26] Printer with ribbon inserted.
A
B
C
E
F
D

User manual ALX 73x | file version 00 | 04/2013 Inserting/replacing ribbon | 13
STARTUP AND OPERATION
ALX
73x
GB
Changing ribbon
With roll diameter monitoring
We recommend switching on roll diameter monitoring,
see section Ribbon reserve on page 29.
As soon as the critical diameter is reached, the mes-
sage appears:
Follow these steps:
1. Open the front cover.
The printer prints the current label completely and
then stops.
As soon as the buffer loop is empty, the dispenser
also stops.
2. Changing a ribbon roll.
3. Close the front cover.
The status message is confirmed automatically.
4. Press the feed key.
The current print job continues.
Without roll diameter monitoring
As soon as the ribbon roll is used up, the following mes-
sage appears:
The printer stops immediately, without printing the cur-
rent label.
1. Open the front cover.
As soon as the buffer loop is empty, the dispenser
also stops.
2. Changing a ribbon roll.
3. Close the front cover.
The status message is confirmed automatically.
4. Press the Enter key to confirm the ribbon end mes-
sage.
FOIL X JOBS
Print status: 5103
Cover open
Print status: 5008
Foil end
Print status: 5103
Cover open

14 | Inserting/replacing ribbon User manual ALX 73x | file version 00 | 04/2013
STARTUP AND OPERATION
ALX
73x
5. Press the feed key.
The last (incomplete) label to be printed will be
printed again. Then printing continues with the cur-
rent print job.
Now the label that was not completely printed must be
removed.
As soon as the label that was not completely printed is
at the front of the buffer loop [27A]:
1. Press the Enter key.
The printer prints the current label completely and
then stops. As soon as the buffer loop is empty, the
dispenser also stops.
2. Remove the label that was not completely printed.
3. Press the feed key.
The print job continues.
[27] Remove the label that was not completely printed when it is at the
front of the buffer loop (A).
A

User manual ALX 73x | file version 02 | 04/2013 Mechanical settings | 15
STARTUP AND OPERATION
ALX
73x
GB
Mechanical settings
Adjusting the core diameter of the
unwinder
Tools:
3 mm hexagonal (Allen) key wrench
The unwinder can be adapted to the internal diameter
of the label rolls using core adapters [28A]. Depending
on this diameter, various adapters will have to be in-
stalled or removed:
38.1 mm (1") core:
Unscrew the bolts [28B] (2 for each adapter) and re-
move the adapters.
76.2 mm (3") core:
Tighten the adapters as shown in figure [28].
101.6 mm (4") core:
Tighten the adapters as shown in figure [29].
Positioning the pressure roller
1. Open the pressure roller [30B]. To do this turn the
lever [30C] until the roll snaps into place.
2. Loosen thumbscrew [30A].
3. Position the pressure roller centred over the back-
ing paper.
4. Close the pressure roller.
5. Tighten the thumb screw.
[28] Position of core adapter for 76.2 mm core diameter.
[29] Position of core adapter for 101.6 mm core diameter.
B
B
A
[30] Adjust the position of the pressure roller (B).
C
A
B

16 | Mechanical settings User manual ALX 73x | file version 02 | 04/2013
STARTUP AND OPERATION
ALX
73x
Position the label sensor on the
dispensing edge
1. Loosen the thumb screw.
2. Push the sensor into place on the axis so that it can
detect the gaps between labels.
LED [31A] is lit when the sensor is standing over a
label.
Position the label sensor in the
printer
The printer is equipped with a combination transmis-
sion/reflex sensor.
By moving the red thumb wheel [32B], you can adjust
the sensor within a range of 80 mm (ALX 734/5) or 100
mm (ALX 736) perpendicular to the material. The dial
shows the currently set value [32A].
Reading the value:
…where:
•Punch position:
Distance of punch from (inner) edge of material
[33A].
•Set value:
Dial value to be set by turning the red wheel.
Example: Punch centre = 11 mm from left edge, sub-
tract 2 mm leaving 9 mm as the setting.
To make the setting, adjust the [32B] wheel until the
required setting is centred on the thumb wheel.
Round labels: To ensure that the start of the label is
correctly detected here, it may be necessary to define
a preset value for the punch offset. This can be set
manually on the printer (parameter PRINT
PARAMETERS > X Print adjust) or using an appropriate
Easy-Plug command.
Set value = punch position – 2 mm
[31] Label sensor at the fixed L-shape dispensing edge.
A
BA
[32] Thumb wheel (B) of the label sensor on the printer.
[33] Measuring the punch position (A)
B
A
A

User manual ALX 73x | file version 02 | 04/2013 Mechanical settings | 17
STARTUP AND OPERATION
ALX
73x
GB
Setting the ribbon tension
For optimum printing results, the ribbon must run with-
out creases. This can be achieved by correctly setting
the torque on the rewinding mandrel and the braking
torque on the unwinding mandrel.
The factory settings cover a wide range of different rib-
bon widths. It may be necessary to readjust the ribbon
tension for very narrow or very wide ribbons.
The braking torque of the ribbon mandrels can be ad-
justed using the red plastic hex bolts [34A] on the rib-
bon mandrels. Turning clockwise increases the torque.
The caps are used to lock the bolts [34B] into place so
that they are not adjusted unintentionally.
The entire length of ribbon must run evenly and crease-
free between the mandrels. The following parameters
are helpful for adjustments:
The ribbon…
•is slack or has creases
•is wound too loosely
Increase unwinding/winding torque (turn bolt clock-
wise).
The ribbon…
•stretches visibly or tears during the printing process
•is not being transported properly
Reduce unwinding/winding torque (turn bolt anti-
clockwise).
[34] Ribbon mandrels on the ALX 73x.
ARibbon rewinding mandrel (without cap)
BRibbon unwinding mandrel
B
A

18 | Mechanical settings User manual ALX 73x | file version 02 | 04/2013
STARTUP AND OPERATION
ALX
73x
Setting the printhead pressure
Different material widths and thicknesses affect the
contact pressure of the printhead on the print roller.
The contact pressure can be set with an adjusting knob
[35A] in 3 stages:
•Stage "I": position for very thin and/or narrow
material
•Stage "II": (pre-setting) position for material of
medium width/thickness
•Stage "III": position for very thick and/or wide
material
Tools: coin or large screwdriver
Setting:
Turn the adjusting knob until the arrow of the knob
[36A] is positioned over the mark for the desired stage.
The adjustment knob locks into 3 position.
CAUTION!
Shortened service life of printhead.
Always set the weakest printhead pres-
sure that will produce acceptable printing
results.
[35] Adjustment knob for printhead pressure (A).
[36] Move the adjustment knob to one of the three locking positions.
A
A

User manual ALX 73x | file version 02 | 04/2013 Mechanical settings | 19
STARTUP AND OPERATION
ALX
73x
GB
Setting the return force of the
unwinder dancer lever
The dancer lever on the unwinder is set so that a wide
range of label materials can be processed without hav-
ing to change the setting of the dancer lever return
force.
Very narrow label material may tear in some circum-
stances or may be stretched so much that dispensing
accuracy is impaired. If this happens, the dancer lever
force must be reduced:
Unwinder with diameter of 400 mm
1. Loosen the lock ring [38B]. To do this turn the ring
opposite to the arrow direction shown here while at
the same time firmly holding the adjusting ring
[38A].
2. Turn the adjusting ring [38A] opposite to the arrow
direction to increase the return force.
Turn the adjusting ring [38A] in the arrow direction
to decrease the return force.
3. Hold the adjusting ring firmly again.
Unwinder with diameter of 300 mm
Tools: 2.5 mm Allen key wrench
Turn the setting screw [39A] on the dancer lever to
the left to increase the return force.
Turn the setting screw [39A] on the dancer lever to
the right to decrease the return force.
[37] Return spring (A) on the dancer lever of the 400 mm unwinder.
[38] Return force adjustment on the dancer lever of the 400 mm
unwinder.
AAdjusting ring
BLocking ring
[39] Return force adjustment on the dancer lever of the 300 mm
unwinder.
A
A
B
A

20 | Mechanical settings User manual ALX 73x | file version 02 | 04/2013
STARTUP AND OPERATION
ALX
73x
Setting the return force of the linear
dancer lever
The linear dancer lever is set so that a wide range of la-
bel materials can be processed without having to
change the setting of the dancer lever return force.
Adjusting the return force:
1. Pull out the knob [40A].
The knob is under spring tension. Hold onto the
knob firmly until it locks into place again.
2. Turn the knob (pulled out) to the desired position.
Adjustment range: 355° (i.e. slightly less than ½
revolution in each direction)
3. Carefully release the knob and allow it to lock into
the desired position.
Do not release the knob until it has locked into
position.
Reducing the return force
Very narrow label material may tear in some circum-
stances or may be stretched so much that dispensing
accuracy is impaired. If this happens, the dancer lever
force must be reduced:
Turn the knob in direction "–".
The direction of rotation for "–" is opposite on LH
and RH machines:
•RH: turn anti-clockwise
•LH: turn clockwise
Increasing the return force
In some cases the label belt may "flutter". This means
that the dancer lever is stretching the label belt be-
tween the dancer lever roll and the dispensing edge too
slowly. If this happens, the dancer lever force must be
increased:
Turn the knob in direction "+".
The direction of rotation for "+" is opposite on LH
and RH machines:
•RH: turn clockwise
•LH: turn anti-clockwise
[40] Knob (A) for adjusting the spring tension on the linear dancer
lever.
A