Avery Dennison ALS 204 User manual

ALS
204/206
256
S ERVICE /I NSTALLATION M ANUAL
Labeller
Edition 8 - 3/2012 - Original version

3
CONTENTS
ALS
20X
256
1 Please observe the following
1.1 General information
1.1.1 Validity and applicability of this manual . . . . . 6
1.1.2 Conventions and information . . . . . . . . . . . . . 7
1.1.3 Notes on installation and repair work . . . . . . . 8
1.2 Safety instructions
1.2.1 Information and qualifications . . . . . . . . . . . . 10
1.2.2 Machine operating safety . . . . . . . . . . . . . . . 12
1.2.3 Safe operation. . . . . . . . . . . . . . . . . . . . . . . . 13
2 Technical Data
2.1 Specifications
2.1.1 Characteristics . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Label sensor . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.5 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.6 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.7 Internal Interfaces . . . . . . . . . . . . . . . . . . . . . 16
2.1.8 Status messages, test functions, product
profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.10 Environmental conditions . . . . . . . . . . . . . . . 17
2.1.11 Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.12 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Dimension diagrams
2.3 Performance data
2.3.1 Label rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.2 Calculation sheet for performance diagrams 21
2.3.3 Dispensing speed over duration v(t) . . . . . . . 23
2.3.4 Dispensing speed over length v(x) . . . . . . . . 24
2.3.5 Dispensed label length over duration x(t) . . . 25
2.3.6 Performance matrix (ALS 256) . . . . . . . . . . . 26
3 Installation and deinstallation
3.1 Unpacking, assembling and
connecting the machine
3.1.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.3 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.4 Attaching the dispensing edge. . . . . . . . . . . 33
3.1.5 Connecting to the mains power supply . . . . 35
3.1.6 Connecting the external operator panel. . . . 38
3.2 Connecting the sensors
3.2.1 Photoelectric label sensor . . . . . . . . . . . . . . 39
3.2.2 Alternative label sensor . . . . . . . . . . . . . . . . 44
3.2.3 Changing light/dark switching at the product
sensor or the alternativ label sensor . . . . . . 47
3.2.4 Photoelectric product sensor . . . . . . . . . . . . 48
3.2.5 Photoelectric roll diameter sensor . . . . . . . . 49
3.2.6 Rotary encoder. . . . . . . . . . . . . . . . . . . . . . . 53
3.3 Decommissioning, Dismantling,
Disposal
3.3.1 Take the machine out of operation. . . . . . . . 56
3.3.2 Dismantling the machine . . . . . . . . . . . . . . . 56
3.3.3 Machine disposal . . . . . . . . . . . . . . . . . . . . . 56
4 Functions
4.1 Function menu
4.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1.2 Notes on the description of functions. . . . . . 59
4.1.3 LABEL SETUP menu. . . . . . . . . . . . . . . . . . 59
4.1.4 MACHINE SETUP menu . . . . . . . . . . . . . . . 60
4.1.5 INTERFACE PARA menu . . . . . . . . . . . . . . 65
4.1.6 SIGNAL INTERFACE. . . . . . . . . . . . . . . . . . 67
4.1.7 SERVICE/DIAGNOS. menu. . . . . . . . . . . . . 71
4.1.8 SERVICE DATA menu. . . . . . . . . . . . . . . . . 73
5 Operation
5.1 Automatic dispensing speed
adjustment
5.1.1 Principle of operation . . . . . . . . . . . . . . . . . . 75
5.1.2 Mounting the rotary encoder . . . . . . . . . . . . 76
5.1.3 Entering the rotary encoder resolution . . . . . 77
5.1.4 Entering the diameter of the measuring
wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.1.5 Entering the rotary encoder type . . . . . . . . . 77
5.1.6 Example: Entering the values for the
recommended rotary encoder . . . . . . . . . . . 78
5.1.7 Calibrating the belt speed . . . . . . . . . . . . . . 78
5.1.8 Calculation scheme for the automatic
dispensing speed adjustment. . . . . . . . . . . . 79

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CONTENTS
ALS
20X
256
5.2 Tandem Operation
5.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.2 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.3 Setting up tandem operation. . . . . . . . . . . . . 83
5.3 Applicator Operation
5.3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.3.2 System requirements . . . . . . . . . . . . . . . . . . 89
5.3.3 Assembly and operation . . . . . . . . . . . . . . . . 89
6 Enhanced Functions
6.1 Access via a Web / FTP server
6.1.1 Web server . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.1.2 FTP server . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.2 Loading Firmware
6.2.1 Loading from memory card. . . . . . . . . . . . . . 95
6.2.2 Download via data interface . . . . . . . . . . . . . 95
6.3 Saving / loading a configuration
6.3.1 Applications. . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3.2 Saving onto a memory card . . . . . . . . . . . . . 97
6.3.3 Loading from memory card. . . . . . . . . . . . . . 98
6.3.4 Automatic loading . . . . . . . . . . . . . . . . . . . . . 98
6.3.5 Loading a configuration via the data
interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.4 Interface commands
6.4.1 Reference table. . . . . . . . . . . . . . . . . . . . . . 104
6.4.2 Immediate commands. . . . . . . . . . . . . . . . . 105
6.5 Forced bootloader start
6.6 Diagnose Dump
6.6.1 Storing diagnosis data . . . . . . . . . . . . . . . . 112
6.6.2 Reading out via serial interface. . . . . . . . . . 113
6.6.3 Storing on CF card . . . . . . . . . . . . . . . . . . . 115
7 Electronics Description
7.1 Wiring Diagrams
7.1.1 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 116
7.1.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . 119
7.2 Electronics Components
7.2.1 ALS 20X . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.2.2 ALS 256 . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.3 Circuit boards
7.3.1 CPU board . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.3.2 Motor driver board . . . . . . . . . . . . . . . . . . . 127
7.3.3 Operator panel board. . . . . . . . . . . . . . . . . 129
7.3.4 Applicator Interface . . . . . . . . . . . . . . . . . . 131
7.4 Power supplies / Transformer
7.4.1 Power supply ALS 20X. . . . . . . . . . . . . . . . 137
7.4.2 Transformer ALS 20x . . . . . . . . . . . . . . . . . 139
7.4.3 Power supply ALS 256 . . . . . . . . . . . . . . . . 140
7.5 Signal Interface
7.5.1 General notes. . . . . . . . . . . . . . . . . . . . . . . 141
7.5.2 Circuit diagrams for signal inputs. . . . . . . . 141
7.5.3 Signals for applicator connection . . . . . . . . 142
7.5.4 Applicator type <--> Signals . . . . . . . . . . . . 143
7.5.5 Signal wave forms of applicator signals. . . 144
7.5.6 Signals for PLC connection . . . . . . . . . . . . 152
7.5.7 Impact of the inhibit signal . . . . . . . . . . . . . 154
7.6 Data interfaces
7.6.1 RS 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.6.2 Connection for external operator panel . . . 157
7.6.3 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.6.4 Integration of the Ethernet interface. . . . . . 158
7.7 Applicator Interface (option)
7.7.1 Important notes . . . . . . . . . . . . . . . . . . . . . 160
7.7.2 Circuit diagrams for signal inputs. . . . . . . . 160
7.7.3 Circuit diagrams for signal inputs. . . . . . . . 161
7.7.4 Power outputs . . . . . . . . . . . . . . . . . . . . . . 161
7.7.5 Pin assignment for applicator connection . 162
7.7.6 Pin assignment for machine status
connection . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.7.7 Pin assignment for product sensor
connection . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.7.8 Signal-LEDs . . . . . . . . . . . . . . . . . . . . . . . . 167
7.7.9 Signal wave forms . . . . . . . . . . . . . . . . . . . 167

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CONTENTS
ALS
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256
8 Fault description
8.1 Types of status messages
8.1.1 Error messages. . . . . . . . . . . . . . . . . . . . . . 168
8.1.2 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.1.3 Setting back a warning . . . . . . . . . . . . . . . . 168
8.1.4 General software errors . . . . . . . . . . . . . . . 168
8.1.5 List of warnings . . . . . . . . . . . . . . . . . . . . . . 168
8.1.6 List of error messages . . . . . . . . . . . . . . . . 169
9 Repair
9.1 Tests
9.1.1 Sensor test . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.1.2 Initial state. . . . . . . . . . . . . . . . . . . . . . . . . . 180
9.2 Power supply ALS 256
9.2.1 Power supply functions. . . . . . . . . . . . . . . . 180
9.2.2 Checking output voltages . . . . . . . . . . . . . . 181
9.2.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 183
9.2.4 Checking the power supply. . . . . . . . . . . . . 185
9.3 Opening the casing
9.3.1 Removing the dust/splash guard . . . . . . . . 186
9.3.2 For machines held in place by side plate or
base plate . . . . . . . . . . . . . . . . . . . . . . . . . 188
9.3.3 For machines held from the
rear side . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9.4 Unwind unit
9.4.1 Expanding mandrel . . . . . . . . . . . . . . . . . . 190
9.4.2 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
9.4.3 Dancer arm . . . . . . . . . . . . . . . . . . . . . . . . 194
9.5 Feed unit
9.5.1 Feed roller unit . . . . . . . . . . . . . . . . . . . . . . 205
9.5.2 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.5.3 Pressure roller . . . . . . . . . . . . . . . . . . . . . . 210
9.6 Rewind unit
9.6.1 Expanding mandrel . . . . . . . . . . . . . . . . . . 213
9.6.2 Dancer arm . . . . . . . . . . . . . . . . . . . . . . . . 215
9.6.3 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

6
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
20X
256
1.1.1 Validity and applicability of this manual
Contents
The complete operating manual for the ALS 204,
ALS 206 and ALS 256 label dispensers consists of the
following parts:
– Operating manual (for operating personnel)
– Service manual (for service personnel)
– Spare parts catalogue (for service personnel)
The present service manual refers exclusively to the
ALS 204, ALS 206 and ALS 256 label dispensers. The
service manual is to be referred to for correct installa-
tion, set-up and adjustment of the label dispenser as
well as for undertaking of repairs. In the description of
repair, only the replacement of high-wear components
is covered. If other components need to be replaced,
e.g. after being damaged due to the effects of an exter-
nal force, please consult the servicing technician at our
sales partner.
Removal and repair of the dispensing edge are not in-
cluded. The labeller can be equipped with various dis-
pensing edges to suit customer requirements. Removal
and repair of the dispensing edge are described in a
separate service manual.
Technical State
Technical state: 10/2011
Software versions:
– Firmware: 1.40
– Applicator Interface: 1.37
Liability
Avery Dennison assumes no liability for damages re-
sulting from improper adjustments or repairs of the ma-
chine. It is assumed that only knowledgeable and ap-
propriately qualified persons are to perform installation,
adjustment, or repairs.
Information about the required qualification: see chap-
ter “Qualification” auf Seite 10.
Copyright notice
All rights to this operating manual are assigned to Avery
Dennison. 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
Manufacturer
Avery Dennison Deutschland GmbH
Ohmstraße 3
D - 85386 Eching
Phone: [phone]
FAX: [phone]
http://www.monarch.averydennison.com
1 PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION

7
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
20X
256
1.1.2 Conventions and information
Explanation of symbols
In order to facilitate legibility and an overview, the vari-
ous types of information used herein are categorised
and identified with certain symbols.
Sentences that are introduced by an arrow contain pro-
cedural 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 fol-
lowed are particularly marked for special attention:
DANGER!
A danger notice indicates an imminent
hazardous situation which, if not avoided,
could result in death or serious injury of the
personnel!
The notice contains instructions on how to
avoid or prevent the danger(s).
The instructions must be followed.
WARNING!
A warning notice indicates risks which could
result in death or serious injury of the
personnel! The notice contains safety in-
structions on how to safeguard possibly af-
fected 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
damage or injury.
The instructions must be followed.
Illustrations
When required, text passages are accompanied by il-
lustrations. 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.
Symbols for keys
– Keys on the operator panel are represented with
symbols
– Where two or more keys must be pressed at the
same time, a "+" appears between the symbols:
+
Functions
Functions are printed in grey text, in the form NAME OF
MENU > Name of function .
Supplemental information
The information symbol indicates notices and
recommendations as well as additional helpful
information.
Auxiliary materials:
– Auxiliary materials, e.g. lubricants, glues or
cleaning agents
Tightening torques:
– Tightening torques for the listed screw con-
nections
If special tools or other aids are needed for a task:
Tools:
– List of the tools and aids that are required for
the following activities

8
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
20X
256
1.1.3 Notes on installation and repair work
General information
Before performing any maintenance or repair work:
Block access to the working area of the machine to
unauthorised persons.
Post a notification sign, which calls attention to the
work.
Electro-static discharge:
When the casing is open, protect the electronics
from damage due to electro-static discharge, e.g.
wear an anti-static arm band.
Tools:
Only use suitable tools.
Ensure all tools are at hand before beginning the
work.
Do not attempt to improvise or to use improper tools,
e.g. loosening an interior-toothed screw (Torx) with
a hexagon socket driver.
Rubber and plastic parts:
Do not allow hoses, seals, and other rubber or plas-
tic parts to come into contact with grease, petrol,
benzene, kerosene or mineral oil.
Environmental protection
Avoid unnecessary waste, e.g. use cleaning cloths
sparingly and reuse packing material.
Only store operating materials, such as fresh or
used cleaning agents, in suitable containers. Never
allow them to enter the sewerage system or to seep
into the ground.
Do not put old batteries, removed parts, and used
cleaning agents in household waste. Dispose of
them in an eco-friendly manner.
Packaging materials:
– Only recyclable materials are used for packaging
the machine.
Dispose of unwanted packaging material in an
eco-friendly manner.
Eco-friendly disposal:
Sort the waste as much as possible, e.g. separate
metals from plastics.
Avoid contaminating the waste if possible.
Drop off the waste at the collection points provided
for that purpose
or
Have the waste collected by suitable recycling
agencies.
Use any on-site options.
Observe all relevant rules, ordinances, and laws.

9
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION
ALS
20X
256
Rules for electromagnetic compatibility
Connect all metallic parts to each other via large
surfaces, ensuring electric conductivity.
– Only polished metal surfaces are electrically con-
ductive. Painted or oxidised surfaces are unsuita-
ble. Aluminium which appears to be polished still
has an invisible oxidation layer on the surface.
– Coated or plated surfaces, though electrically con-
ductive, can reach very high resistance values at
high frequencies (skin effect).
Clean contact surfaces, polish the metal, use fan
disks (washers) or mounting plates.
Carry out EMC grounding, preferably as a neutral
(star) point. A neutral (star) point prevents loops.
When laying the signal lines and power cable,
space them apart.
Lay all control and signal lines at least 50 cm distant
from power cables (e.g. motor line). Minimum dis-
tance in the switch cabinet: 20 cm.
Spatially lay out all the lines in the switch cabinet as
close as possible to the reference potential.
Lead the signal lines into the unit or switch cabinet
from one side only.
– The more lines that are laid in front and in back be-
tween the switch cabinet and the machine, the larg-
er the radiation surface of the radiated
electromagnetic energy.
Lead the signal lines out of the machine (in one
bundle and from one location, if possible) and into
the switch cabinet.
Twist together unshielded lines from the same cir-
cuit.
– This reduces interference effects of various kinds.
Wire inductive components to suitable interference
suppressors.
– Possible inductive components: Relay, solenoid
valve
– Possible interference suppressors: Diodes, varis-
tors, RC combinations
House all components suspected of being sources
of RF interference fields in a closed metal casing
(Faraday screen).
Shield all signal and control lines.
Ground the shielding on both sides at its large sur-
faces.
For insufficient potential equalisation between the
shielding lines: Lay an additional equalisation lead
parallel to the shielding with a cross section at least
10 mm2.
Avoid equalisation currents in the shielding of the
signal lines
– Equalisation currents can arise between subassem-
blies with different grounding conditions.
When the grounding conditions are different, only
shield the side with the better grounding condition.
Only shield both sides when the grounding condi-
tions are the same (e.g. inside a machine).
Power filter
Mount the power filter direct at the power supply.
Connect the filter casing to the EMC grounding via
large metal surfaces.
Lay all lines as close as possible to metal parts,
even reserve cables
– Freely hanging lines act as transceiver antennas.
Ground all reserve cables and unused wires in the
cables at least at one end.
Keep the cables as short as possible
– Cable resistance and signal distortion increase with
the length of the cable.

10
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
20X
256
1.2.1 Information and qualifications
Qualification
Ensure necessary qualifications
Only allow appropriately qualified personnel to set
up, adjust, and repair the labeller, e.g. mechanical
and electronics specialists.
Only allow work on the electronics system to be
done by authorised electronics technicians.
Clearly define the responsibilities for installing, set-
ting up, adjusting, and repairing the labeller. Con-
sistently adhere to the responsibilities.
Qualification for system integrators and service
technicians („service personnel“)
Knowledge required to install the print dispens-
er and perform service work must be demon-
strated through appropriate qualification. Only
service personnel with technical training are able to as-
sess 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 manu-
facturer.
– 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.
1) For example faults when detecting labels 2) For example incorrect labelling
[1] An example of the distribution of tasks among different qualified
personnel
Tasks System integrator Operator Service technician
Install 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 1XX X
Clean the machine X X
Rectify major operating faults 2X
Settings to the electronics/ mechanics X
Repairs X
Manual: Service manual Operating Manual Service manual, spare
parts catalogue
1.2 SAFETY INSTRUCTIONS

11
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
20X
256
Pay attention to the information
WARNING!
Reliable and efficient operation of the label-
ler is only guaranteed if all necessary infor-
mation is observed!
Carry out the installation, connection,
programming, setting, and repairing of
the machine exclusively in accordance
with the specifications in this manual.
Observe additional safety and warning
notices attached to the labeller.
Observe and adhere to all relevant ordi-
nances and rules in their applicable form.
Examples:
– Work place regulation
– Accident prevention regulations
– Trade union regulations for occupational
safety and health
– Equipment safety law
– Recycling and waste management law
Information must be made available
This service guide
must be made available to all persons who are ent-
rusted with installing, setting up, adjusting, or repai-
ring the labeller.
must be maintained in legible condition.
must be made available to the new owner if the ma-
chine is sold.
Safety and warning notices attached to the labeller
must be kept clean and legible. Missing or damaged
warning plates are to be replaced.

12
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
20X
256
1.2.2 Machine operating safety
Installation, maintenance
WARNING!
Improper usage of the machine can lead to
accidents, material damage and loss of pro-
duction!
When installing the labeller, check for
visible shipment damage. Immediately in-
form Avery Dennison of any damage.
When installing the machine on a support
stand, make sure that it can not tip over.
Only put the labeller into operation if it is
in flawless condition.
Only perform alterations or conversions
to the labeller with the consent of Avery
Dennison's customer service.
Only use original replacement parts.
WARNING!
Danger of body part trapping and pinching at
the dispensing edge due to products moving
in the conveyor direction!
Take appropriate measures to prevent
personnel from reaching between a pro-
duct and the dispensing edge; e.g. install
a protective guard or shield.
WARNING!
Before starting up the machine:
Carry out test runs using the task-speci-
fic settings under near production condi-
tions.
Only put the machine into operation after
at least one successful test run has been
completed.
Protection measures in applicator mode
WARNING!
Danger of crushing between dispenser edge
and applicator pressure plate due to
applicator movement!
Prevent personnel from reaching bet-
ween dispensing edge and applicator by
installing higher-level protective equip-
ment 1.
1) Movable, locked, separating protective equipment (EN ISO
12100-1, 3.25.4)
After all servicing or repair work
WARNING!
Risk of an accident due to moving or loose
parts!
Re-install all covers and safety equip-
ment.
Check for firm seating of all screw con-
nections that were loosened during the
work.
Remove all tools and other aids used du-
ring service and repair from the working
area of the labeller.
Verify flawless functioning of all safety
equipment.
WARNING!
This unit operates at mains voltage! Coming
into contact with electrically live compo-
nents can cause potentially lethal electrical
shocks and burns.
After assembling, check the printer ac-
cording to the regulations relevant in
your country.

13
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
20X
256
1.2.3 Safe operation
Protect against injuries that can result
from electrical current
WARNING!
Contact with energised components can re-
sult in life-endangering currents through the
body as well as burns. The label dispenser is
connected with the mains supply!
– Only allow work on the electronics sys-
tem to be done by authorised electronics
technicians.
Observe the following information uncon-
ditionally.
Power connection:
If the power switch is not accessible due
to the installation position of the machi-
ne, a suitable accessible separator has to
be provided by the system integrator.
The device is only completely disconnected
from the mains if the power cable is un-
plugged.
Make sure the power supply socket is ac-
cessible.
In case of emergency, switch off the de-
vice and disconnect the power cable.
(ALS 20xALS 104 with splash guard) The
power cable cannot be pulled off from the
machine side power connector .
If the machine is connected to a cabinet,
a suitable and accessible power separa-
tor must be provided by the system inte-
grator.
Before any repair work:
Detach the machine from power supply.
Check to ensure it is de-energised.
Secure the power supply against uninten-
tional or unauthorised switch-on.
Casing:
Before opening the casing pull the power
plug.
– The casing may only be opened by
trained personnel and when the machine
is de-energised.
Only put the machine into operation when
the rear wall of the casing is correctly in
place.
If the machine must be switched on while the
casing is open for repair or inspection:
Never touch energised components. This
also applies to components with low vol-
tages.
Ensure the flawless condition of the electri-
cal system:
Regularly check the electrical equipment.
Only connect the machine to other machi-
nes if these meet the requirements for a
SELV circuit, in accordance with
EN 60950.
Re-tighten loose connections.
Immediately replace damaged lines.
After assembling, check the printer ac-
cording to the regulations relevant in
your country.

14
1PLEASE OBSERVE THE FOLLOWING
1.2 SAFETY INSTRUCTIONS
ALS
20X
256
Protection against injuries that can result
from mechanical actions
WARNING!
Acute risk of injury and long-term bodily in-
jury from working with heavy loads!
Lift or carry the machine with a minimum
of 2 persons. If possible, use a crane or
other lifting device.
Only use suitable and defect-free restrai-
ning devices during transportation and
installation.
Never allow the machine to stand with
loosened mounting brackets, not even for
a short time.
If the machine is fastened to a movable
support: Ensure it can not tip over.
WARNING!
Risk of accident due to uncontrolled ma-
chine start-up!
Before doing any repair work, switch off
the machine and pull the power plug.

15
2TECHNICAL DATA
2.1 SPECIFICATIONS
ALS
20X
256
2.1.1 Characteristics
1) The maximum usable dispensing speed depends on the label geometry.
2) At a dispensing speed range of 5 m/min to the max. speed
2.1.2 Labels
3) Depending on the dispensing edge width.
2.1.3 Label sensor
2.1.4 Power supply
4) For more information on fuses, see section “Replacing fuses” auf Seite 55.
5) Not accessible for user or service technician.
Dispensing speed 1):
ALS 204
ALS 206
ALS 256
max. 40 m/min
max. 30 m/min
max. 50 m/min
Labelling halt precision 2)
at the peeling edge:
±1mm
Speed control: Fixed setting or automatic
speed adaption via the
rotary encoder
Label material: Converted self-adhesive
label material with liner
Internal rewinding yes
Material width (including
backing paper) 3):
ALS 204
ALS 206
ALS 256
up to 110 mm
up to 160 mm
up to 160 mm
Label width:
ALS 204
ALS 206
ALS 256
10-110 mm
10-160 mm
10-160 mm
Label length: 5 to 600 mm
Label roll:
Winding direction
Dispenser (outer) Ø:
Rewinder (outer) Ø:
Core (inner) Ø:
inner or outer
up to 300 mm
up to 200 mm
38.1 / 76.2 / 101.6 mm
(1.5/3/4")
Distance to peel edge
L-shape dispensing
edge:
V-shape dispensing
edge:
19 mm
77 mm
Sensor type: Transmission sensor;
NPN/PNP (switchable)
System voltage:
ALS 20X
ALS 256
110 V (AC) at 60 Hz
power frequency (permis-
sible tolerance ±10%)
230 V (AC) at 50 Hz
power frequency (permis-
sible tolerance ±10%)
100-240 V (AC) at
50-60 Hz power frequen-
cy (permissible tolerance
±10%)
Power consumption:
ALS 20X
ALS 256
max. 460 VA
max. 560 VA
Fuses:
ALS 20X
ALS 256
F1, F2: T5AH 250 V 4)
Fuses integrated in the
power supply 5)
2 TECHNICAL DATA
2.1 SPECIFICATIONS

16
2TECHNICAL DATA
2.1 SPECIFICATIONS
ALS
20X
256
2.1.5 Electronics
2.1.6 Interfaces
2.1.7 Internal Interfaces
6) Not yet available
2.1.8 Status messages, test
functions, product profiles
Processor: 32 Bit CPU MIPS Core
RAM: 16 MBytes
ROM: 4 MBytes
Slot for memory card: 1x CompactFlash
Realtime clock: n. a.
Control panel: graphical display with
128 x 32 pixels, 2/4 lines,
5 buttons
Sensor interfaces for
external sensors
Label sensor:
Alternative label
sensor:
Product sensor:
APSF-sensor (Rotary
encoder):
Stock sensor:
(plug in each case 4-
pin M12)
NPN, 24 V
PNP/NPN, 24 V
PNP/NPN, 24 V
single-phase/two-phase,
PNP/P-P, 24 V, max.
20 kHz
PNP, 24 V
Internal sensor interfac-
es:
Material unwinder
Pressure roller
Dancer arm
Light barrier
not used
bi-phase light barrier en-
coder
PLC interface
Outputs:
Inputs:
Sub D15, optically insu-
lated, optionally via two
8-pin M12 (separate in-
puts/outputs in each
case)
4x PNP, 24 V, a maxi-
mum of 500 mA/channel,
total permissible output
current: 1500 mA
3x PNP/NPN, 24 V
Data interfaces:
Serial:
Ethernet:
USB:
CF card:
Control panel
interface:
RS232C (Sub-D9),
max. 115 200 Baud
10/100 BaseT (RJ45)
Device V1.1 (USB B),
‘Full speed’ operating
mode, 12 MBit/s
Slot for 1 CompactFlash
card
RS 485 (Mini DIN 6 con-
nection) for remote con-
trol
RFID Connection for RFID
read/write unit (special
equipement) 6)
Applicator Interface Connection for Applicator
Interface (AI) board (spe-
cial equipement)
Connector for additional
motor driver
not used
Automatic halt, if ... the label roll is spent or
no gap was found.
...the max. admissible
number of missing labels
is reached.
Test functions: Automatic diagnostics
check when switched on
Output of system data via
data interface
Status indicators: Label counter
Operating hours counter
Storage locations for
product profiles:
up to 16

17
2TECHNICAL DATA
2.1 SPECIFICATIONS
ALS
20X
256
2.1.9 Dimensions
6) Measurements without the dispensing edge bracket and dispensing edge
2.1.10 Environmental conditions
2.1.11 Integration
2.1.12 Certificates
– CE, TÜV-Mark, FCC, CCC, GOST, CTÜVUS -Mark
– The regulation DIN EN 55022 demands for class A
devices the following text to be printed in the
manual:
„WARNING: This is a class A product. In a domestic
environment this product may cause radio
interference in which case the user may be required
to take adequate measures.“
– The FCC regulation demands the following
information text for class A devices:
„NOTE: This equipment has been tested and found
to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection
against harmful interference when the equipment is
operated in a commercial environment. This
equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in
accordance with the instruction manual, may cause
harmful interference to radio communications.
Operation of this equipment in a residential area is
likely to cause harmful interference in which case
the user will be required to correct the interference
at his own expense“
Width x height x depth: 6)
ALS 204
ALS 206
ALS 256
492 x 488 x 371 mm
492 x 488 x 402 mm
492 x 488 x 402 mm
Weight:
ALS 204
ALS 206
36 kg
38 kg
Operating temperature: 5 to 40°C
Humidity: 30 to 85%, (non-con-
densing)
Noise
(at a distance of 1 m):
72 dB(A)
Protection class: IP 21
IP 65 special equipment
for ALS 20X
Mounting positions: side / bottom / rear
Labelling positions: top / side / bottom
Dispensing edges: V-shape
L-shape
fixture 90° pivoting

18
2TECHNICAL DATA
2.2 DIMENSION DIAGRAMS
ALS
20X
256
[2] Dimensions of the ALS 20X / ALS 256– part 1
74
86
84330(204)/380(206/256)
414 (204)/464(206/256)
132(204)/182(206/256)
111(204)/161(206/256)
118
60
140
226
431
226
431
173
248
474
75
24
32
298
205 266
471
2.2 DIMENSION DIAGRAMS

19
2TECHNICAL DATA
2.2 DIMENSION DIAGRAMS
ALS
20X
256
[3] Dimensions of the ALS 20X / ALS 256 - part 2
ALS 204 ALS 206/256
341
402
492
488
205 320

20
2TECHNICAL DATA
2.3 PERFORMANCE DATA
ALS
20X
256
2.3.1 Label rate
[4] The maximum label rate (number of labels per minute) depends
on the dispensing speed and on the label length.
Prerequisites:
– Direct dispensing (without applicator)
– No printer attached
Reading example [5]:
Given a label length of 25 mm (including the gap) and a
dispensing speed of 20 m/min, a maximum of approx.
750 labels per minute can be dispensed.
The exact value can be calculated with the „Calculation
sheet for performance diagrams“, see ch. 2.3.2 (p. 21).
[5] Reading example of the maximum label rate.
2.3 PERFORMANCE DATA