Novexx Solutions ALS/XLS 204 Bedienungsanleitung

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

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

Service Manual ALS 20x/256/272

05/2019 4Contents

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

Service Manual ALS 20x/256/272

05/2019 5Contents

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

Service Manual ALS 20x/256/272

05/2019 6Contents

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

Service Manual ALS 20x/256/272

05/2019 7Contents

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

Service Manual ALS 20x/256/272

05/2019 8Contents

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.

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: +49-8165-925-0

FAX: +49-8165-925-231

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.

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