Avery Dennison ALS 204 User manual

ALS
204/206
256
INSTALLATION MANUAL
Labeller
Edition 1 - 4/2013 - 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 . . . . . 4
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical State . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Copyright notice . . . . . . . . . . . . . . . . . . . . . . . . . 4
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Conventions and information . . . . . . . . . . . . . 5
Explanation of symbols . . . . . . . . . . . . . . . . . . . . 5
Warnings concerning dangers and risks . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Symbols for keys . . . . . . . . . . . . . . . . . . . . . . . . . 5
Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Supplemental information . . . . . . . . . . . . . . . . . . 5
1.1.3 Notes on installation and repair work . . . . . . . 6
General information. . . . . . . . . . . . . . . . . . . . . . . 6
Environmental protection. . . . . . . . . . . . . . . . . . . 6
Rules for electromagnetic compatibility. . . . . . . . 7
1.2 Safety instructions
1.2.1 Information and qualifications . . . . . . . . . . . . . 8
Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pay attention to the information. . . . . . . . . . . . . . 9
Information must be made available . . . . . . . . . . 9
1.2.2 Machine operating safety . . . . . . . . . . . . . . . 10
Installation, maintenance. . . . . . . . . . . . . . . . . . 10
Protection measures in applicator mode . . . . . . 10
After all servicing or repair work . . . . . . . . . . . . 10
1.2.3 Safe operation. . . . . . . . . . . . . . . . . . . . . . . . 11
Protect against injuries that can result from
electrical current . . . . . . . . . . . . . . . . . . . . . . . . 11
Protection against injuries that can result from
mechanical actions . . . . . . . . . . . . . . . . . . . . . . 12
2 Installation and deinstallation
2.1 Unpacking, assembling and
connecting the machine
2.1.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.3 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
For machines held from the rear side . . . . . . . . 15
Holding machine in place by side plate or base
plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.4 Attaching the dispensing edge . . . . . . . . . . . 18
L-shaped dispensing edge . . . . . . . . . . . . . . . . 18
V-shaped dispensing edge . . . . . . . . . . . . . . . . 19
Adjustable dispensing edge holder . . . . . . . . . .19
2.1.5 Connecting to the mains power supply . . . . 20
Checking the supply voltage setting . . . . . . . . .21
Plugging in the power lead . . . . . . . . . . . . . . . .22
2.1.6 Connecting the external operator panel. . . . 23
Mounting the external operator panel . . . . . . . .23
2.2 Connecting the sensors
2.2.1 Photoelectric label sensor . . . . . . . . . . . . . . 24
Connecting the photoelectric sensor . . . . . . . . .24
Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . .24
Connection diagram . . . . . . . . . . . . . . . . . . . . .25
Adjusting the Avery sensor . . . . . . . . . . . . . . . .26
Switching the Avery sensor - PNP/NPN . . . . . .27
Adjusting the Wenglor photoelectric sensor
automatically . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Adjusting the Wenglor photoelectric sensor
manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.2.2 Alternative label sensor . . . . . . . . . . . . . . . . 29
Connecting the sensor. . . . . . . . . . . . . . . . . . . .29
Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . .29
Connection Diagram . . . . . . . . . . . . . . . . . . . . .30
Example: capacitive label sensor . . . . . . . . . . .30
2.2.3 Changing light/dark switching at the product
sensor or the alternativ label sensor . . . . . . 32
Gen. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Gen. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2.2.4 Photoelectric product sensor . . . . . . . . . . . . 34
Connecting the photoelectric sensor . . . . . . . . .34
Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . .34
Connection Diagram . . . . . . . . . . . . . . . . . . . . .34
2.2.5 Photoelectric roll diameter sensor . . . . . . . . 35
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Connecting the OD sensor . . . . . . . . . . . . . . . .36
Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . .36
Connection diagram . . . . . . . . . . . . . . . . . . . . .36
Enabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Setting the roll diameter. . . . . . . . . . . . . . . . . . .37
Function test . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.2.6 Rotary encoder. . . . . . . . . . . . . . . . . . . . . . . 39
Requirements for rotary encoder: . . . . . . . . . . .39
Connecting the rotary encoder . . . . . . . . . . . . .40
Connection diagram . . . . . . . . . . . . . . . . . . . . .40
2.3 Decommissioning, Dismantling,
Disposal
2.3.1 Take the machine out of operation. . . . . . . . 41
2.3.2 Dismantling the machine . . . . . . . . . . . . . . . 41
2.3.3 Machine disposal . . . . . . . . . . . . . . . . . . . . . 41

4
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: 01/2013
Software versions:
– Firmware: 2.50
– Applicator Interface: 1.38
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” on page 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
1PLEASE OBSERVE THE FOLLOWING
1.1 GENERAL INFORMATION

5
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

6
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.

7
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
circuit.
– 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.

8
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 1XXX
Clean the machine X X
Rectify major operating faults 2X
Settings to the electronics/ mechanics X
Repairs X
Manual: Installation manual,
Service manual
Operating Manual Service manual,
spare parts catalogue
1.2 SAFETY INSTRUCTIONS

9
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.

10
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.

11
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.

12
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.

13
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
2.1.1 Transport
CAUTION!
To avoid damaging the machine during
transport:
Only transport the machine in its original
packaging.
Keep the original packaging for a later
transport.
2.1.2 Unpacking
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.
CAUTION!
To avoid damaging the machine during un-
packing:
Never hold the machine by the deflection
rollers, dancer arm or rewind or unwind
unit.
Lift the machine out of the packaging with at least
two persons.
– To do so, hold the machine by its casing.
After unpacking, check the machine for visible ship-
ment damage.
Alternatively, the machine can be lifted with a
crane.
To do so, screw an eye ring M10 into the lo-
cation shown in [2A].
[2] Attachment of an eye ring M10 (A) for transportation with a
crane.
A
2INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE

14
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
2.1.3 Setting up
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.
Prerequisites:
Support stand with a tube end providing the following
measures:
– Outer diameter: 60 mm
– Wall thickness: minimum 5 mm
The machines offer three attachment points for mount-
ing to the support:
– Rear side
Requires a fixing bolt to be mounted on the rear side
of the machine. A joint [3B] is used to attach the
fixing bolt to the support. Advantage: The machine
can be inclined both side to side and forwards and
backwards.
– Side plate
Requires a flange [3A] to be mounted on the side
wall of the machine.
– Base plate
Requires a flange [3C] to be mounted on the base of
the machine casing.
[3] Attachment points
C
B
A

15
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
For machines held from the rear side
– Order number for fixing bolt assembly [4A] (includ-
ing screw and cylinder pins): A7621
Tools:
– 17 mm hexagon socket driver
– 8 and 10 mm hexagon socket drivers
Locate the two cylinder pins [4B] in the holes in the
fixing bolt [4A].
Screw the fixing bolt [5B] onto the flange on the rear
side of the machine with the screw provided [5C].
– The two cylinder pins must locate into the holes [5A]
in the flange.
– Mount the fixing bolt with its bevelled side pointing
inwards towards the machine.
Tightening torque:350 Nm
[4] Fixing bolt (A) for clamping the machine from the rear side.
The cylinder pins (B) prevent rotation of the fixing bolt.
A
B
[5] Mounting the fixing bolt (B).
B
A
C

16
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
WARNING!
Danger of injury by the machine falling to
ground.
– This danger exists if the machine is to be
mounted so as enable sideways swivel-
ling, i.e. if the pin in the joint is vertical. If
the machine is mounted incorrectly [7], it
will fall to the ground as soon as the set
screws clamping either the top or bottom
half of the joint pin are loosened.
Always mount the head joint assembly to
the machine with the clamp pointing
downwards [6].
Wear safety footwear during mounting.
[8] AHead joint element
BJoint axis
Assemble the two halves of the head joint [9A] with
the joint pin [9B] as shown. Tighten the set-screws
at the joint axis.
Slide one half of joint over the trunnion (bolt-on cy-
linder) on the machine and tighten the screw [9A].
– Observe the warning notice (see above). Mount the
head joint assembly with the clamp pointing side-
ways or downwards.
Lift the machine and slide the free end of the head
joint over the end of the support tubing. Tighten the
set-screw [9B].
Tightening torques:
– Set-screws at machine and
stand [9A, B] . . . . . . . . . . . . . . . . . . . 45 Nm
– Set-screws at the joint axis [8C] . . . . 45 Nm
[6] Correctly mounted head joint assembly. The clamp on the
machine-side of the joint is pointing downwards!
[7] Wrongly mounted head joint assembly. The clamp on the
machine-side of the joint is pointing upwards!
A
A
C
B
C
[9] Assembling the two halves of the head joint (A) with the
joint pin (B).
B
A

17
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
Holding machine in place by side plate or
base plate
– Order number for flange plate assembly [10C] (in-
cluding screws and washers): A7622
Tool:
– 8 mm hexagon socket driver
Screw the flange plate [10C] to the side or base of
the machine.
– Use the four screws provided in delivery (ISO 4762
(DIN 912) M10x25).
Lift the machine and slide the clamp over the end of
the tubing of the support. Tighten the set-screw
[10A].
Tightening torque:
– set-screw [10A] . . . . . . . . . . . . . . . . . 45 Nm
Blind hole depth: 13 mm
[10] Attachment points
B
C
A

18
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
2.1.4 Attaching the dispensing edge
L-shaped dispensing edge
Tools:
– 8 mm hexagon socket driver
Both the dispensing edge holder [12D] and the mount-
ing flange on the machine casing have two concentric
rings of holes [12B] on the connecting surfaces. Two
pins [12C] that fit into these holes are provided with the
dispensing 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 dispensing head
holder can be adjusted in 15° increments [13].
Locate the pins in diametrically opposite holes.
– Choose either inner or outer circle of holes, depend-
ent on angle required.
Fit the dispensing edge holder onto the pins at the
required angled.
Fix the dispensing edge holder in place with
screw [12A].
[11] Dispensing edge holder with dispensing edge.
[12] Attaching the dispensing edge holder (D).
[13] The mounting of the dispensing edge holder assembly can
be adjusted in 15° gradations as required
D
C
AB

19
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
V-shaped dispensing edge
Tool:
– 8 mm hexagon socket driver
Mount V-shaped dispensing edge as shown
– The angle of the V-shaped dispensing edge cannot
be changed. It is mounted without fixing pins.
Adjustable dispensing edge holder
Tool:
– 8 mm hexagon socket driver
The standard dispensing edge holder can be replaced
by the optional adjustable dispensing edge holder [15],
which enables a height adjustment of the dispensing
edge.
– Adjustment range: 70 mm in steps of 0.2 mm [17]
– Mounting is possible in different angles in steps of
15°, as with the standard dispensing edge holder
– Article no.: RH A8018, LH A8138
Adjusting:
Rotate the adjustment wheel [15A], until the inten-
ded height is reached.
[17] Adjustment range of the adjustable dispensing edge holder.
[14] V-shaped dispensing edge in place.
[15] Adjustable dispensing edge holder.
AAdjustment wheel
BSpindle
[16] Adjustable dispensing edge holder in place.
A
B
70 134

20
3INSTALLATION AND DEINSTALLATION
2.1 UNPACKING, ASSEMBLING AND CONNECTING THE MACHINE
ALS
20X
256
2.1.5 Connecting to the mains
power supply
WARNING!
The machine is connected with the mains
supply! Contact with energised components
can result in life-endangering currents
through the body as well as burns.
Ensure that the machine is switched off
before connecting power cable.
(ALS 20X) Only operate the machine at
the mains voltage rating set at the voltage
selection switch.
(ALS 20X) Ensure that the machine is cor-
rectly adjusted to your local supply volta-
ge.
(ALS 256) Only operate the machine
using the system voltage indicated on the
nameplate.
Only plug machine in to a correctly ins-
talled socket with an earth contact.
The length of the power cable must not
exceed 3m.
Only by disconnecting the plug from the
mains supply is the machine fully discon-
nected from the supply. Therefore:
Keep mains connection freely accessible.
(ALS 20X with splash guard) Provide a se-
parate mains power separator.
In case of danger switch off the machine
and unplug the power cable.
[18] Power supply connection (A) at the ALS 20X.
A