Novexx ALX 924 User manual
Edition 4 - 9/2016 - A106807 - Translation of original version
USER MANUAL
ALX 92x
Print & Apply System
User Manual ALX 92x
09/2016 3Content
Content
Please note -7
General notes -7
Validity of this manual and required compliance -7
How information is represented -8
For your safety -10
Intended use -10
Information and qualification -10
Operating safety of the machine -12
Every time before starting production -14
Warning notes on the machine -15
Product description -17
Overview -17
Designs -17
Configurations -17
Functionality -18
Operating components -19
Control panel -21
Connections -22
Technical Data -23
Dimensions -23
Connection, device data -24
Label material -24
Performance data -25
Automatic ribbon economy -28
Thermal transfer ribbon -30
Mechanical features -30
Ambient conditions -31
Interfaces -31
Electronic equipment -32
Certificates and Markings -32
Options -33
External control panel -33
Roll diameter sensor -33
Applicator interface (AI) -33
Signal interface (USI) -34
RS232/422/485 interface -34
Ribbon core adapters -34
Pressure roller -35
Blow-on applicator LA-BO -35
Tamp-on applicator LTP/LTPV -35
Tamp-on applicator LA-TO -36
Swing-on applicator LA-SO -36
Long dispensing edge -36
User Manual ALX 92x
09/2016 4Content
Operating modes -37
Overview -37
Online mode -38
Offline mode -40
Standalone mode -43
Parameter menu -44
Overview of parameter menu -44
Information about the parameter description -44
PRINT PARAMETERS menu -45
SYSTEM PARAMETER menu -47
SPECIAL FUNCTION menu -48
SERVICE FUNCTIONS menu -49
Startup and Operation -50
Electrical connections -50
Connecting to the mains power supply -50
Connecting to a data host -51
Connecting sensors -52
Inserting label material -53
Inserting the label roll -53
Threading in the label web -54
Replacing a label roll -58
Inserting/replacing ribbon -59
Inserting ribbon -59
Changing ribbon -60
Mechanical settings -61
Position the label sensor -61
Setting the ribbon tension -62
Setting the printhead pressure -63
Switching on/off -64
Switching on -64
Switching off -64
Setting and monitoring the machine -65
Settings in parameter menu -65
Monitoring functions -66
Printing -68
Creating print jobs -68
Installing the printer driver -68
Transferring a print job -68
Status messages -70
Error messages -70
List of error messages -70
User Manual ALX 92x
09/2016 5Content
Cleaning & Maintenance -73
Cleaning instructions -73
Safety -73
Cleaning agents -73
Cleaning interval -73
General cleaning -74
Printhead -75
General notes -75
Cleaning the printhead -76
Replacing printheads -78
Testing the printhead -79
Rubber rollers -80
Deviator rollers -81
Backing paper deviator roller -81
Sensor -82
Cleaning the punch sensor -82
Cleaning the material end sensor -83
Cleaning the ribbon path -84
Replacing the filter liner -85
EU Declaration of Incorporation -86
Appendix regarding the Declaration of Inc-orporation -87
User Manual ALX 92x
09/2016 | 01 7Please note
Please note
GENERAL NOTES
Validity of this manual and required compliance
Contents
The complete operating manual for the ALX 924, ALX925 and ALX 926 print & apply systems con-
sists of the following parts:
This operating manual refers exclusively to the machine types listed above. It is used for proper
operation and adjustment of the machine.
The machine must be properly installed and configured to allow for operation and settings.
For information about the required qualification, see section Information and qualification on
page 10.
For information about installation and configuration, see the service manual.
For technical questions not covered in this operating manual:
Follow the instructions of the service manual for the label dispenser
or
Request a service technician from our sales partner.
Our sales partner's customer service department is available especially for configuration settings
and malfunctions.
Technical release
Technical release: 2/2016
Software version: 6.60
Liability
Novexx Solutions reserves the right:
• to make changes in design, parts and software and to use equivalent parts instead of those
specified for the purpose of technological progress.
• to change information in this manual.
Any obligation to extend these changes to machines previously delivered is excluded.
Copyright
Novexx Solutions retains all rights to this manual and its appendices. Reproduction, reprint or any
other type of duplication, including parts of the manual, are permitted only with written approval.
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 Must be ordered
separately a
a) Only for certified and qualified service technicians or OEM partners.
Spare parts catalogue
User Manual ALX 92x
09/2016 | 01 8Please note
Manufacturer
Novexx Solutions GmbH
Ohmstrasse 3
D-85386 Eching, Germany
Tel.: +49-8165-925-0
Fax: +49-8165-925-231
www.novexx.com
How information is represented
Explanation of symbols
To enhance readability and make information easier to find, different types of information are iden-
tified:
Instruction with no order of tasks assigned
1. Numbered instructions introduced by preceding text
2. The specified order must be followed!
Special note for action that must be performed.
Explanation of an error cause in the reference of error messages.
• Enumeration of features
• Other feature
The Experts symbol identifies activities that are reserved exclusively for qualified and spe-
cially trained personnel.
The information symbol identifies notes and recommendations as well as additional infor-
mation.
Notes about hazards and risks
Important instructions that must absolutely be followed are specially highlighted:
Illustrations
Illustrations appear in the text where required. References to these illustrations are shown in
[square brackets] containing the number of the illustrations. Uppercase letters after an illustration
number, for example [12A], refer to the corresponding item within the illustration.
Normally the machine is shown as the right version. The left version is only shown if there is a need
to make a distinction.
WARNING!
A warning symbol refers to risks that can result in severe or fatal injuries! The note contains safe-
ty measures to protect affected persons.
Instructions must be followed without exception.
CAUTION!
A caution symbol refers to risks that can result in property damage or personal injury
(minor injuries). The note contains instructions for preventing damage.
Instructions must be followed without exception.
User Manual ALX 92x
09/2016 | 01 9Please note
Key symbols
Keys in the control panel are represented as text, for example "Press the ONLINE key".
Parameters
Parameters in the parameter menu are represented in the format MENU NAME > Parameter name in
grey type.
User Manual ALX 92x
09/2016 | 00 10 Please note
FOR YOUR SAFETY
Intended use
Print & Apply systems of the ALX 92x series are designed for printing, dispensing and applying self-
adhesive labels using the direct thermal or thermal transfer procedure. The individual versions
(ALX 924, ALX 925, ALX 926) differ in the maximum print width.
Various combinations of thermal transfer ribbons and label materials are used and must be availa-
ble in the form of rolls.
The label material that is used must be punched, i.e. the self-adhesive labels adhere individually,
separately by punchings, on a carrier material. The labels must only adhere strongly enough so that
they will come loose when the material is deflected over a sharp edge.
Any other type of or more extensive application will be considered non-intended use.
NOVEXX Solutions shall assume no liability for damage resulting from non-intended use of the ma-
chine.
Information and qualification
Ensuring the necessary qualification
Only fully trained and authorised personnel are permitted to operate, adjust and maintain the
machine.
Service work must only be performed by qualified and appropriately trained technical specialists
(service technicians) or the customer service department.
Areas of responsibilities for operating and servicing the machine must be clearly defined and
consistently observed.
Personnel must also be regularly instructed in on-the-job safety and environmental protection.
Qualification for operation
The instruction provided for the operating personnel must ensure:
• that the operating personnel can use the machine independently and without danger.
• that the operating personnel can rectify minor operating faults (for example a paper jam) inde-
pendently.
At least 2 persons should be instructed in operation.
Have a sufficient quantity of label materials available for tests and instruction.
Qualification for system integrators and service technicians
Knowledge required to install the Print & Apply system and perform service work must be
demonstrated through appropriate qualification. Only service personnel with technical train-
ing are able to assess the tasks to be performed and recognise potential dangers.
• Knowledge acquired through technical training in mechanics and electronics (for example in
Germany the training to become a mechatronics engineer).
• Participation in a technical training course for the corresponding label dispenser offered by the
manufacturer.
• The service personnel must be acquainted with the functionality of the label dispenser.
• The system integrator must be acquainted with the functionality of the of the system into which
the label dispenser is being integrated.
User Manual ALX 92x
09/2016 | 00 11 Please note
Making note of information
Any product liability and warranty claims will not be valid unless the machine is operated according
to the instructions in the operating manual.
Keep product information at hand
This operating manual
must remain readily available for operating personnel at a location near to the machine
must be kept in legible condition.
If the machine is sold, it must be made available to the new owner.
The safety and warning symbols and messages on the machine must be kept in a clean and
legible state. Replace any signs that are damaged or missing.
Tasks System integrator Operator Service technician
Mount the machine X
Connect X
Make settings X
Switch on/off X X X
Insert/change material/ribbon X X X
Application-related settings X X X
Rectify minor operating faults a XX X
Clean the machine X X
Rectify major operating faults b X
Settings to the electronics/ mechanics X
Repairs X
Manual: Service manual,
Installation manual Operating Manual Service manual,
spare parts catalogue
[Tab. 1] An example of the distribution of tasks among different qualified personnel.
a) For example faults when detecting labels
b) For example incorrect labelling
WARNING!
The label dispenser can only be operated safely and efficiently by complying with all of the requi-
site information!
Before beginning operation, read this operating manual and follow all of the instructions.
Observe all additional safety and warning information given on the label dispenser.
Only technically knowledgeable persons are permitted to operate the label dispenser and
make settings on it.
User Manual ALX 92x
09/2016 | 00 12 Please note
Operating safety of the machine
Intended use
The machine must only be used in accordance with the specifications in section Intended use
auf Seite 10.
Warning of injuries due to electrical shock
WARNING!
This unit operates at mains voltage! Contacting electrically live components can cause lethal
electrical shocks and burns.
The device is only completely disconnected from the mains if the power cable is unplugged.
Make sure the power supply socket is accessible.
In case of emergency, switch off the device and disconnect the power cable.
Installation:
Only operate the machine when the enclosure is properly installed.
The machine must only be connected by an authorised technician who is acquainted with the
associated dangers.
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.
Keep the machine's On/Off switch accessible.
Cleaning:
Before cleaning and maintenance, switch off the machine and pull out the main plug.
Keep the machine dry.
If a liquid gets into the machine, switch off the machine immediately and unplug the mains
contactor. Notify a service technician.
CAUTION!
If the supply voltage is too high or too low, the machine may be damaged.
Only operate the unit at the mains voltage given on the type plate.
Ensure that the mains voltage set on the machine corresponds to the local mains
voltage.
User Manual ALX 92x
09/2016 | 00 13 Please note
Warning of injury hazards from mechanical components
WARNING!
Danger of injury due to moving and rapidly rotating parts!
Maintain a safety clearance from the machine when it is in operation.
Never reach into a machine that is running.
Switch off the machine before making any mechanical adjustments.
Keep clear of the area around moving parts even when the machine is stopped if there is any
possibility of the machine starting up.
Dancer levers work by spring tension and may snap back if the track tension of the label material
suddenly decreases.
Always keep clear of the range of motion of the dancer levers.
Entanglement hazard!
When working in the vicinity of machines in operation, do not wear ties, loose clothing items,
jewellery, wrist watches or similar objects on your body.
Long hair must be kept in a hair net and must not be worn loose.
Crushing hazard on the dispensing edge due to products on the conveyor equipment!
If the machine is running or ready for operation, never reach between the product and the dis-
pensing edge.
Never remove or bypass the protective equipment to prevent reaching in while the machine
is in operation.
Tripping hazard!
Lay the connection cable and pneumatic hoses (if fitted) so that no one can trip over them.
Danger of injury caused by falling label roll!
Wear safety shoes.
In applicator mode:
Danger of crushing between dispenser edge and applicator pressure plate due to applicator mo-
vement!
The applicator must only be operated with higher-level protective equipment a.
If the machine is running or ready for operation, never reach between the applicator and the
dispensing edge.
Never remove or bypass the protective equipment to prevent reaching in while the machine
is in operation.
a) Movable, locked, separating protective equipment (EN 953)
User Manual ALX 92x
09/2016 | 00 14 Please note
Every time before starting production
Due diligence of the operator and service personnel
Ensure that the following requirements are met in accordance with details specified in the ser-
vice manual:
• The machine must be set up and configured to meet applicable requirements.
• All necessary safety equipment must be installed.
• The machine must have successfully completed at least one test run.
• The machine must be connected to the energy supply.
Make the requisite personal protective equipment available to the operating personnel, for ex-
ample hair nets. Ensure that the protective equipment is used properly.
Due diligence of the operating personnel
Check the safety equipment to ensure it is working correctly.
Check the machine for visible damage. Report defects that are discovered immediately.
Use personal protective equipment properly, for example wearing a hair net.
Remove material and objects that are not required from the working area of the machine.
Ensure that only authorised persons remain in the working area of the machine.
Ensure that no one can be endangered by the machine starting up.
User Manual ALX 92x
09/2016 | 00 16 Please note
[2] Warning notes on the ALX 92x
Warning note Meaning Article no.
The ´Pinch point´ warning note warns you of
the danger posed by the machine´s rotating
parts; they can trap items and draw them in.
A5346
The "Hot surface" symbol warns of a burn ha-
zard if the surface is touched. Allow the de-
vice to cool off before touching it.
A5640
The blue label ´Read manual´ demands that
operators read the user manual. A5331
[Tab. 2] Meaning of the warning notes.
User Manual ALX 92x
09/2016 | 01 17 Product description
Product description
OVERVIEW
Designs
ALX 734/735
The ALX 92x is available in versions ALX 924, ALX 925 and ALX 926. These two versions differ in
the width of the printhead:
• ALX 924: 4" print width (106 mm)
• ALX 925: 5" print width (127 mm)
• ALX 926: 6“ print width (160 mm)
ALX 73x RH/LH
Each machine of series ALX 92x is available as a right-hand (RH) or left-hand (LH) version [3]:
• ALX 92x RH: The label exits the machine on the right.
• ALX 92x LH: The label exits the machine on the left.
[3] ALX 92x LH and RH.
Configurations
The ALX 92x can be adjusted in many ways to meet customer requirements:
Feature Adjustment
Direction in which products move Selection of design: LH / RH
Assembly position of the machine Horizontal / vertical (for labelling from above or
from the side)
Label application Direct dispensing or by means of an applicator
[Tab. 3] Options for configuring the ALX 92x.
RHLH
User Manual ALX 92x
09/2016 | 01 18 Product description
Functionality
The main function of the ALX 92x is printing, dispensing and applying self-adhesive labels. The
printing is done using the thermal or thermal transfer process. „Dispensing“ means completely or
partially separating the label from the backing paper. The backing paper is afterwards wound up by
the machine. Applying the label is done directly after the dispensing edge by means of a pressure
roller, or by means of an applicator.
Sequence of print dispensing:
• A print job is transferred to the printer (via database interface or memory card). Afterwards, the
machine is ready to print.
• The machine prints and dispenses a label as soon as a start signal arrives (coming e. g. from
an external product sensor at a conveyor). In „direct dispensing“ mode [4A], the label is at-
tached directly off the dispensing edge onto the product by means of a pressure roller
• In applicator mode [4B], the ALX 92x is equipped with an additional unit, the applicator, which
takes over the label after dispensing and attaches it onto the product.
[4] ALX 92x in operating mode „Direct Dispensing“ with pressure roller (A) and in applicator mode with applicator LTPV (B).
User Manual ALX 92x
09/2016 | 01 19 Product description
Operating components
[5] Operating components of the ALX 92x RH.
AMaterial unwinder
The unwinding mandrel receives the material roll (fitting the core diameter with removable
adapter rings).
BGuiding rod
Holds the rolls on material unwinder and backing paper rewinder.
CMaterial web dancer lever
Holds the label material evenly under tension. Brakes the rotation of the material roll if the ma-
terial tension drops.
DBacking paper rewinder
Rewinds the remaining backing paper.
EBacking paper dancer lever
Holds the backing paper evenly under tension. Controls the rewinding speed.
FControl panel
Displays the device operating status; for defining settings in the parameter menu.
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User Manual ALX 92x
09/2016 | 01 20 Product description
[6] Operating components of the print module in an ALX 92x RH.
AControl panel
Displays the device operating status; for defining settings in the parameter menu.
BFront cover
Held open by gas pressure spring. Inside: Insert diagram showing the path of the labelling ma-
terial and ribbon.
CRibbon unwinding mandrel
Holds the ribbon roll.
DRibbon winding mandrel
Winds up the used ribbon.
EMaterial guides
The material end sensor is located inside the material guide.
FPrinthead
GPressure lever
HAdjustment wheel for label sensor
IAdjustment knob for printhead pressure
JLocking lever for pressure roll at the feed roller
A
B
C
D
EF
GH
I
J
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