Automatic Splicer MODEL SP-1

Transcription

1 Automatic Splicer MODEL SP-1 Version V Operation and Maintenance Manual BUTLER AUTOMATIC INC BUTLER.AUTOMATIC.INC Campanelli Business Park 7 Routes des Jeunes 41 Leona Drive CH-1227 Acacias Geneva USA- Middleborough, MA Switzerland Tel. (1) Tel. (41) Fax (1) Fax (41) Website : butler@butlerautomatic.com 1

2 NOTICE Butler Automatic Incorporated supplies all data necessary for the proper instruction, operation, testing, and maintenance of its products. Butler Automatic retains all proprietary rights in and to the information disclosed. This information shall not be reproduced, copied, or used in whole or in part for purposes other than those for which it is furnished, without written authorization from Butler Automatic Inc. A copy of the Operators Manual is furnished with each Splicer. Additional copies can be purchased from the Customer Service / Parts Department, Butler Automatic Inc., 41 Leona Drive, Middleborough MA (508) We suggest that you copy the information from your machine nameplate into the space above label. DISCLAIMERS Information in this document is subject to change without notice. Butler Automatic Inc., reserves the right to make changes to machine features, specifications, components and/or control systems, without notice. These machines are constructed for maximum operator safety when used under standard operating conditions, for the purpose intended, when recommended instructions are followed. All personnel engaged in the use of the machine should become familiar with its operation as described in this manual. PROPER OPERATION OF THE MACHINE PROMOTES SAFETY FOR THE OPERATOR AND ALL WORKERS IN THE VICINITY. Particular attention MUST be paid to the appropriate pages of this manual where WARNINGS and CAUTIONS are clearly written for your protection. Becoming familiar with materials, machine inspection, speed limitations, guard maintenance and total user responsibility, will assist you in learning potential areas in need of observation for danger. In reading the guidelines for safety in the manual, it should be recognized that it is the responsibility of each individual to observe the safety rules as outlined. ALL WARNING and CAUTION labels must be observed and obeyed. ALL ACTUAL or POTENTIAL danger areas must be reported. Butler Automatic disclaims all liability for any damages, which may result from disregard of safety and operator instructions detailed in this manual. WARNING! CARELESS OR INCORRECT LOADING AND UNLOADING OPERATIONS CAN CAUSE HAZARDOUS CONDITIONS, WHICH MAY RESULT IN SERIOUS INJURY TO PERSONS OR EQUIPMENT. 2

3 Table Of Contents NOTICE 2 DISCLAIMERS 2 WARNING! 2 TABLE OF CONTENTS 3 TECHNICAL CHARACTERISTICS SP1 SPLICER 6 MAXIMUM REGISTER MARK DISTANCE: CONSULT FACTORY 6 SPLICER OPERATION NOTE! 8 WARNING AND CAUTION LABELS 8 OPERATING SAFETY 13 A. ROLL LOADING/ROLL REMOVAL 13 B. WEB-UP 13 C. SPLICE PREPARATION 13 D. MACHINE GUARDS 13 E. UPPER AND LOWER ROLL AREAS 13 F. ACCUMULATOR / DANCER AREA 13 G. SPLICE HEAD PROTECTIONS 13 H. LOCKOUT/TAGOUT SAFETY PRECAUTIONS 14 I. E-STOP 14 SIDELAY CONTROL TOUCHSWITCHES 32 FAULT INDICATOR FLASHING. STATUS ALARM. 33 FAULT CONDITIONS 33 OPTIONAL CONTROLS. 34 INITIAL ROLL LOADING/WEBUP 38 PNEUMATIC ROLL DRIVE LIFTERS 38 WEBBING UP THE SPLICER 54 GO TO RUN 56 THE SPLICE CYCLE 56 OPERATIONAL DIFFERENCES 56 SPLICE MODE VARIATIONS 56 SPLICE ACTUATION 56 AUTO-SPLICE BY ROLL DIAMETER 57 TAPE APPLICATION 68 IN-REGISTER SPLICING 72 REGISTER SWITCH SETTINGS 72 SETUP 73 MEASURE DISTANCE 74 WEB PATH THROUGH SENSOR ASSEMBLY 79 SPLICER MAINTENANCE AUTOMATIC SPLICE ACTUATION 82 3

4 THE SPLICE CYCLE 83 OPERATIONAL DIFFERENCES 83 SPLICE MODE VARIATIONS 83 CORE DETECTOR SENSOR OPERATION 85 QC50 CORE DETECTOR SENSOR 87 FEATURES 87 OVERVIEW 88 SENSOR CONFIGURATION 89 OUTPUTS 89 SENSING MODES 89 RUN MODE 89 SENSOR PROGRAMMING 90 SENSOR PROGRAMMING CHART 90 REVIEW OF SETTINGS 90 NON-INITIALIZATION DISPLAY MESSAGES 91 END OF ROLL TAPE SENSOR OPTION 92 SETUP: 94 END OF ROLL TAPE SENSOR CALIBRATION 95 SIDELAY CONTROL 96 AUTO ALIGNER SIDELAY (SENSOR) 97 EXAMPLE OF ALIGNER OPERATION. 98 OTHER OPTIONS- ALERT INDICATORS 100 INTERFACE OPTIONS 101 NIP BAR REPLACEMENT 101 REPLACING THE CUT KNIFE 102 ATTENTION! 102 KNIFE BLADES ARE EXTREMELY SHARP. 102 TAKE PARTICULAR CARE NEAR THE KNIFE AND WEAR GLOVES OR PROTECTION. 102 INSTRUCTIONS FOR REPLACEMENT OF KNIFE HOLDER ASSEMBLY 103 KNIFE CYLINDER REPLACEMENT 106 REINSTALLATION 106 REPLACEMENT OF CUT KNIVES 107 REPLACING THE KNIFE PIVOT SPRING. 108 SPLICING HEAD PIVOT SECTION ALIGNMENT 109 REGISTER SENSOR INFORMATION 111 SENSOR GAP 112 SENSOR ANGLE 112 SENSOR PROGRAMMING 112 TEACH THE REGISTER MARK SENSOR. 113 STATUS 1, NORMAL, ON OR OFF

5 STATUS 2, ALARM STATE. 115 WEB PATH THROUGH SENSOR ASSEMBLY 117 DRIVE SYSTEM SERVICE 120 ROLL DRIVE DIRECTION CHANGE. 120 ROLL DRIVE BELT REVERSAL. 120 ROLL DRIVE BELT REPLACEMENT. 120 ROLL DRIVE BEARING REPLACEMENT. 120 DRIVE MOTOR REMOVAL 120 DRIVE MODULE DISASSEMBLY 124 BELT REMOVAL 126 BEARING REPLACEMENT 129 CALIBRATIONS & TROUBLESHOOTING 131 W.I.F. & W.O.F. SENSORS 133 W.O.F. SENSOR. 1 SENS. 133 W.I.F. SENSOR. 10 SENS. 134 W.I.F. & W.O.F. SENSORS 135 DANCER SENSORS. 137 DANCER ZONE SENSORS. 2, 3 SENS. 138 DANCER EMPTY SENSOR. 7 SENS. 139 AUTO-SPLICE/IMMINENT SENSORS 140 SETTING THE AUTO-SPLICE DIAMETER. 142 SPLICE IMMINENT ALARM 142 ADJUSTABLE FORCE VACUUM 143 SYSTEM FAULTS 146 ADDITIONAL L.E.D. INFORMATION. 146 SYSTEM FAULT INDICATOR 146 FAULT INDICATOR FLASHING. STATUS ALARM. 147 FAULT CONDITIONS 147 APPENDIX A- GENERIC SPLICER TERMS GLOSSARY 151 5

6 SPLICER OPERATION Technical Characteristics SP1 Splicer Model shown is mm diameter capacity and mm width. Drawings are available for each model. AUTOMATIC SPLICER SP1 Specifications are Model Dependant Specifications on chart are for mm wide model EMPTY WEIGHT (Varies with model width) : 18 Diameter lbs. 500 kg 24 Diameter 1300 lbs. 590 KG POWER SUPPLY : 220 VAC Single Phase 60Hz 2.50kW AIR : AIR CLEAN AND DRY PSI (6-8 bar) (30Nl/mn maxi) MAXIMUM SPEED : fpm depending on configuration MATERIAL: Flexible films, paper ad laminates MAXIMUM ROLL DIAMETER : mm / mm / mm CORE DIAMETER : 2.75, 3, 5, 6 MAXIMUM ROLL WEIGHT: 275 lbs. or consult factory MAXIMUM WEB WIDTH : 9.5, 13, 19, 25, MAXIMUM REGISTER MARK DISTANCE: Consult Factory 6

7 HEALTH AND SECURITY INSTRUCTIONS This splicer has been made to maximize operator safety provided the machine is used under the specified operating conditions and the recommended instructions in this manual are followed. Any operators using this machine must familiarize themselves with the operating procedures and set forth in this manual. Correct operation of the machine will help insure the safety of the operator and those near the machine. Special attention must be paid to those pages in this manual which describe warnings and precautions necessary for your protection. It is the operators responsibility to familiarize themselves with all aspects of this manual to properly utilize the equipment and to gain better understand the areas of the machine which demand particular attention to insure operator safety. It is each operator s responsibility to read and follow all safety and operational indications contained in this manual. The zones of real and potential danger are indicated in this manual. Butler Automatic refuses all responsibility for damages caused by operator inattention or misuse of the equipment excepting indications contained in this manual. GENERAL SAFETY INSTRUCTIONS ATTENTION To avoid accidents or damage to the equipment : Be vigilant and use common sense. Familiarize yourself with the safety and operating instructions contained in this manual. Learn the zones of the equipment which require extra precautions for security. All personnel using the equipment must be properly trained and follow the operating procedures contained in this manual which help guard safety of the operator and those around the equipment. All personnel engaged in the use of the splicer must learn its operation prior to attempting any splicing. PROPER OPERATION PROMOTES SAFETY FOR THE OPERATOR AND ALL WORKERS IN THE VICINITY. For your own protection, pay particular attention to all WARNING and CAUTION LABELS, on the machine, and those noted in this manual. For your safety pay particular attention to all safety related items in this manual Take care near moving equipment. Never touch a moving web or part of the machine. Never leave tools or objects on a running machine, as they may fall and cause damage. Never make machine adjustments while the equipment is in use. Use caution around the machine when it is in operation. Do not place your hands close to moving rollers. Use some other means to clear the machine. Do not make any adjustments or repairs to the equipment, unless you are qualified to do so. 7

8 Do not make any modifications to the equipment, or attempt to defeat any safety features. Do not remove any guards, machine covers, or other parts of the splicer. Keep machine doors closed and secured at all times. Report any accidents to your supervisor immediately. Report any missing guards or machine damage to your supervisor immediately. NOTE! In some of the illustrations in this manual, the machine guards may have been removed. This has been done purely for illustrative purposes only and should not be done under any condition for normal machine operation. WARNING AND CAUTION LABELS As with any machinery within an industrial environment, certain precautions must be observed and performed to avoid personal injury or damage to the machine! Some of the Figures within this manual may show or illustrate components without the machine guards in place or the warning and caution labels affixed. This has been done for illustrative purposes only! DO NOT ALLOW THE SPLICER TO BE OPERATED WITH ANY OF THE GUARDS REMOVED OR ANY LIMIT SWITCHES BYPASSED OR INOPERATIVE! FOLLOW THE INSTRUCTIONS ON THE WARNING AND CAUTION LABELS AT ALL TIMES! IF ANY LABELS OR GUARDS ARE MISSING FROM THE MACHINE, DO NOT OPERATE THE SPLICER! CONTACT BUTLER AUTOMATIC INC. FOR REPLACEMENT PARTS. In the following section, there are reproductions of the graphic sections of the Safety, Warning, Caution and Danger Labels that may appear on the Butler Splicers. The purpose of the label will be explained, following the illustration. IN ADDITION, THERE ARE PHOTOGRAPHS OF TWO LOCK-OUT/TAG-OUT POINTS ON THE SPLICER. P Caution, Mechanical Hazard. Pinch Point/Crush Hazard Keep hands and fingers clear of this area. The machinery parts, in this area, could cause an injury by compression of hands or fingers. 8

9 P Danger, Mechanical Hazard. Cut Hazard. Keep hands and fingers clear of this area while operating the machinery. The machinery parts, in this area, could cause an injury by cutting hands or fingers. Lock out power and compressed air sources before servicing the machine. P Warning, Mechanical Hazard. Entanglement Hazard (Belt Drive). Moving parts can crush and cut. Keep guards in place. Lock out power and compressed air sources before servicing the machine. P Caution, Burn Hazard Hot Surface. Some Splicers may he equipped with Heat-Seal Splicing Heads. These Splicing Heads contain parts that may reach temperatures that could cause a burn. Allow these parts to cool before servicing. 9

10 P Energy Hazard(s) Notice. Lock Out in the De-Energized State. This equipment is supplied with an electrical disconnect that may be locked (Locked Out) with the power kept in the OFF (De-Energized) state. Always shut off and lock out the electrical power before servicing the machinery. MAIN POWER SWITCH. This switch controls the incoming power to the splicer. Electrical System Locked Out 10

11 This equipment is supplied with a pneumatic disconnect that may be locked (Locked Out) with the compressed air kept in the OFF (De-Energized) state. Always shut off and lock out the pneumatic supply before servicing the machinery. Pneumatic System Locked Out P Electrical Hazard. Danger. Electrical Shock Hazard. This equipment is supplied with High-Voltage Electricity. Contact with electrical components will cause electrical shock or burn. Turn off and lock out power before servicing. B THIS UNIT HAS MORE THAN ONE POWER SOURCE. TO AVOID ELECTRIC SHOCK, DISCONNECT ALL SOURCES BEFORE SERVICING. B English B French B German Electrical Hazard. Danger. Electrical Shock Hazard. This equipment is supplied with Electrical Power from more than one source. (Example: Process Machine power for Emergency Stop Circuit). Contact with electrical components will cause electrical shock or burn. 11

12 Turn off and lock out ALL POWER before servicing P General Hazard. Warning. No access for unauthorized persons. Avoid injury. This unit is to be serviced by trained personnel only. 12

13 OPERATING SAFETY A good machine operator is always conscious of safety. Long hair should be bound up, jewelry and watches should be removed, and loose clothing should be secured. The following areas of potential hazard should be noted: A. ROLL LOADING/ROLL REMOVAL MAKE SURE the roll is fully supported by the Roll shaft. DO NOT stand under a suspended load at any time. Take special care when opening and closing shafts to follow operator instructions contained in this manual and pay attention of devices when loading and unloading rolls. (Zone 1) B. WEB-UP DO NOT touch any roller until you are sure that it has stopped rotating. Rollers may appear to be stationary while they are still rotating. Touching a moving roller can cause injury to hand or arm. C. SPLICE PREPARATION DO NOT touch the Running Roll Lead-in Roller(s) until you are sure they have stopped rotating. Touching a moving roller can cause injury to hand or arm. Stay away from moving SPLICING HEAD PARTS. Wait for completion of cycle before attempting SPLICE PREPARATION. DO NOT attempt any correction to a Prepared Splice while a splicing cycle is under way. (Zone 2) Splice head knives are protected by guards, but operators should use caution when in their proximity. When cutting the web for splice preparation take all precautions to avoid cutting yourself. Use gloves or follow your plants standard safety procedures. D. MACHINE GUARDS Never remove the machine guarding and interlocking protections. Be aware of all guards and the dangers they are guarding. Report any missing or damaged guards. E. UPPER AND LOWER ROLL AREAS The design and configuration of the roll drive system minimizes any risk to the operator. It is the operators responsibility to keep clear of the roll drive. (Zone 1) F. ACCUMULATOR / DANCER AREA The dancer is a gravity powered system which is designed to minimize any operator risk. The operator should be prudent an use common sense to avoid any moving parts in this area of the machine. (Zone 3) G. SPLICE HEAD PROTECTIONS The splice head is composed of an upper and lower half. Only the half of the head which corresponds with the web which is not unwinding should be opened during run for splice preparation. For proper splicing, the two halves of the splice head must remain closed after 13

14 the splice has been prepared. Opening the head during the splice cycle will interrupt and stop the action of the nip and or cut knife. The mechanical design of the splice head nip action causes the head to stay locked closed while the nips are actuated and the knife can be energized. The tip of the knife is rounded to minimize cut risk from direct contact. H. LOCKOUT/TAGOUT SAFETY PRECAUTIONS Both the Electrical System and the Pneumatic System have been provided with lockable disconnects. (See Page 5, 7-9, for examples). These disconnects must be secured with whatever devices and tags your company provides. The electrical disconnect interrupts the High Voltage Supply to the Splicer. The pneumatic valve not only interrupts the compressed air supply to the Splicer, it also vents air pressure from within the splicer to atmosphere. I. E-STOP The Splicer E-Stop button must be joined to the process E-Stop circuit allowing the splicer and production line to be rapidly stopped in case of danger. To restart the machine the E- Stop switch must be mechanically deactivated by turning it, then the reset button must be pressed. 14

15 SECURITY DURING MAINTENANCE It is the responsibility of maintenance personnel, as with machine operators, to familiarize themselves with all aspects of machine operation. Maintenance personnel must follow the instructions found in the section OPERATING SAFETY. All personnel concerned with maintenance of this equipment must pay particular attention to the following: A. General Never lubricate or clean a machine which is in operation. Never make adjustment to the machine under power or in operation. Always use appropriate lock out procedures as prescribed by your company for machinery. A machine that is not locked out must be considered dangerous and may start as part of the process machine to which it is connected. Only trained, qualified and authorized personnel should perform work of any kind on this machine. Replace defective parts with Butler standard parts only. Never replace fuses with fuses of a higher rating. B. Electrical Danger Certain elements of the splicer are always under power and dangerous. Cut the electric circuit before starting work on the splicer. The main interrupter is lockable and must be locked out to make certain that the machine stays safe during maintenance, and avoid power being restored to the machine during repair or maintenance. Lockout tag out is provided on the exterior of the electrical control enclosure as well as on the disconnect mounted inside the enclosure. C. Security during work on the pneumatic system Extreme attention must be given to any work performed on tubing and the pneumatic system of the splicer. Air must be removed and locked out before any service is performed on the pneumatic system. If a tube detaches, compressed air or particles many cause injury. D. Dancer zone Never work in the dancer zone when it is moving or under tension. The dancer should be blocked in position by unwinding web to fill the dancer and removing any tension from the web. If work must be performed with the dancer raised, the dancer must be blocked in position. Never rely on the web to hold the dancer in position. E. Splice head zone The cut knives are very sharp. Use extreme care when working with or around the knife assembly. The knives may be accessible during a maintenance intervention on the splicing head. Place a shield around the knives or remove the knife assembly before starting work in the splice head. Be careful to follow plant safety rules and use protective gloves if required. 15

16 INTRODUCTION The automatic splicer from Butler is a machine which permits rolls of materials to be unwound into a production line and automatically spliced to eliminate process stops and associated waste from roll change over. The splicer automatically controls unwinding process tension and joins in a new roll assuring a continuous flow of paper into the production process. The Butler SP-1 splicer is known as a «zero speed splicer due to the fact that the splice is performed with the new web stopped and the process fed from the integral accumulator. This manual and instructions presents the technical characteristics and proper usage, control, installation and maintenance of the Butler Series SP-1 splicer. This splicer is designed for Low Tension operation. With the In-Register Option, splices can be made to precisely keep the printed image alignment through roll change over. Standard SP1 Splicers are manufactured to accept one of three different roll diameters. 18 [450 mm], or 24 [600 mm]. 30 (750 mm). Standard web widths are 9.5 [235mm], 19 [475 mm], 25 [625 mm], 29 [725 mm] or 35 [875 mm]. This machine has an integral Drive System, which is used to drive the rolls of material, for unwinding and control of the web feed at low tension. The Splicing Head allows for One-Step Splice Preparation. The Splice Joint is prepared on the same Vacuum Nip Bar that is used to seal the webs together at Splice Time. OVERVIEW OF THE SPLICER (A) This figure shows the Operator Side of the Splicer and the Splicing Head. This is a Left-Hand Splicer. Viewed from the Operator Side, the Web exits to the viewers left. SP1 Splicers are available in Left-Hand or Right-Hand configurations, as needed. 16

17 DESCRIPTION 17

18 General Elements The SP-1 splicer is composed of three primary elements: 1) The roll unwind 2) The splice head 3) The festoon / Accumulator 18

19 MACHINE OVERVIEW The following section shows web up and the general sequence of function of the SP-1 automatic splicer system. WEB UP WEB UP COUNTER CLOCKWISE ROLL ROTATION The splicer can be configured for either clockwise or counter clockwise unwind to accommodate rewind orientation or operation with a turn bar. See maintenance section for information on direction conversion. 19

20 WEB UP WEB UP CLOCKWISE ROLL ROTATION Web introduction and passage. The passage as shown in either the CW or CCW web up diagram must be followed for proper function of the splicer. The web is first passed through the splice head and then pass the turn roller and into the accumulator. The passage of the web through the accumulator is done by passing the web in an S around the rollers in the fixed upper position and the moveable dancer rollers. This passage creates the festooning which is the storage needed as a buffer to feed the process while the splice is completed. 20

21 Refilling the accumulator. The roll is driven by the roll drive modules to unwind and refill the accumulator. The dancer rolls descend and create the garlands of the accumulator as web is fed, which is the accumulated reserve to create a buffer for automatic splicing. Upon start up the roll will unwind faster than the process to fill the accumulator. Running Position. Until the dancer rollers reach the equilibrium position, the accumulator is refilled to bring these rollers to their normal run position fully filled. When the dancer reaches its full running position, the unwind velocity is controlled to match the unwind speed with the process speed and hold the dancer steady. Roll Loading. The empty core position is used to load the new roll which will be prepared for the next splice. 21

22 Splice Preparation. The new roll is placed into position on the open shaft position. The operator places the end new web onto the vacuum preparation bar and applies adhesive. (See Splice Preparation) 22

23 Splice Cycle. When the running roll reaches a preset diameter, the control automatically actuates the splice cycle. (The splice is also equipped with a manual splice button) The expired roll is slowed to a stop. The web is pressed onto the leading edge of the prepared new roll which is held on the vacuum preparation bar. The old web is severed off. During this change the process is fed from the reserve in the accumulator. The new roll then unwinds to refill the accumulator and the splicer is ready for a new roll of material to be loaded. The new roll unwinds into the machine. The splicer is ready for a new roll of material and a new splice preparation for the next automatic roll change. No production loss. Automatic roll splicing increases process productivity, while reducing waste and down time. 23

24 OPERATION OF SPLICER Operator Controls The operator control panel must be used for operation of the splicer, including splice preparation and running the machine. For ease of use, the control panel is located next to the splice head. 24

25 Upper Roll Select Register Splice Vacuum Manual Splice Fault Indicator Lower Roll Select Sidelay Reset E-Stop Optional Autoalign Splice Actuation Select Knife Release 25

26 MAIN POWER SWITCH. This switch controls the incoming power to the splicer. Main Switch Lockout. The switch may be locked in the off position, while the splicer is being serviced or an operator is entering unsafe zones in the machine. We recommend that operators consult with their plant safety personnel and rules to ensure they use this feature in accordance with plant safety regulations. 26

27 EMERGENCY STOP BUTTON. The RED, Emergency Stop pushbutton is the Splicer Stop Button. It MAY also be used to stop the Process Line. (This function requires additional wiring on the part of the customer). To stop your splicer, push the button IN. The button assembly is a locking (detent) arrangement. Once the button has been pushed in, it will remain locked in. Before re-starting the machine, rotate the button clockwise, to allow it to spring OUT, and restore normal operations. After releasing the Emergency Stop Button, push the RESET Button. RESET BUTTON. This GREEN Push-button is used to start or restart the splicer. If power to the splicer is interrupted or, if the Emergency Stop Pushbutton is used, the RESET Button must be pushed IN, to return to the operational state. 27

28 Operator Touch Panel NEVER USE A HARD OR SHARP OBJECT ON THE PANEL. USE YOUR FINGERS ONLY, FOR SWITCH OPERATION. Upper and Lower Roll Select Touch Switches This button allows the operator to select the running roll. This is used when the machine is being started up and is only activated when the machine is not pulling web. Upper/Lower Roll Graphic Use this Touch Switch, to select the Upper/lower Roll as the Running Roll. 28

29 When ON, the GREEN L.E.D. Indicator at the Upper Left corner, confirms that the Upper Roll has been selected as the running Roll, A similar Touch Switch is used to select the Lower Roll. Splicing Head Graphic The Splicing Head Graphic contains four L.E.D. Indicators and three Touch Switches. Manual Splice The manual splice button allows the operator to actuate a splice manually by pressing the splice button. The indicator Splice Ready must be illuminated for the machine to be ready for splice. Preparation of a splice will automatically leave the machine in the ready state for splice. If the splice is not prepared, at splice time the splice ready light will flash as a warning indicator. Manual Splice Graphic When the Green L.E.D. at the Upper Left Corner, is ON, the SP-1 Splicer is ready to accept a Splice Command, either from the Automatic Splice Diameter Sensing System, or from this Manual Splice Touch Switch. In order for the Splice Ready L.E.D. to come on; 1). The Vacuum must be ON. 2). The Splicing Head must have been opened since the last splice. 3). Both sections of the Splicing Head must be closed. «Splice Ready» Indicator The light on the manual splice button illuminates to indicate that the splicer is ready to perform a manual or automatic splice. This light will flash warning if the splicer has reached splice imminent diameter and the machine has not been made ready for splice, or another fault is present. 29

30 If the roll runs down to the Auto-Splice Diameter, and the Splicer is not Ready, the Splicer OK Signal to the Press/Process Line will be dropped and the Line should stop. It should be noted that register splice requires web to be fed into the process. If the machine is stopped, pressing manual splice with register turned will not actuate a register splice. At stop, the accumulator is at the bottom, so feeding web is not possible. Thus after pressing the splice button, the system will time out after 5 seconds and a non register splice will be made. Vacuum The vacuum select button on the splice head allows the operator to manually turn on and off the vacuum supplied to the non running side of the splice head on the vacuum preparation bars. The vacuum will automatically turn on to the prep bars when the splice head is opened. When the splice head is closed and the splice ready indicator is illuminated, the splice head must be opened to turn off the vacuum manually. This is done to avoid an inadvertent loss of vacuum and the resulting missed splice. Vacuum Graphic Vacuum, for holding the web in the Splicing Head is supplied by an integral venturi or optional vacuum pump system. During Splice Preparation, the Vacuum System will normally be turned ON, automatically, when one of the Splicing Head sections is opened, after a splice. After a splice has been completed, the Vacuum System will be turned off automatically. The Green L.E.D. Indicator at the Upper Left Corner will be ON or OFF, to show the state of the Vacuum System. The Vacuum Touch Switch may be used to manually control the Vacuum System. At the end of the Splice Cycle, the Vacuum is automatically turned off, when it is no longer needed. THE VACUUM SYSTEM CANNOT BE TURNED OFF MANUALLY, IF BOTH SECTIONS OF THE SPLICING HEAD ARE CLOSED. To turn the Vacuum System off, manually, you must open one section of the Splicing Head and press the vacuum button again. If you wish to turn the vacuum ON or OFF Manually, press the Vacuum button when one section of the splice head is open. If the vacuum has been turned of manually, the vacuum will not turn on automatically when the head is opened until after the next splice has been made. In this case vacuum will need to be turned on when needed by pressing the selector switch. 30

31 Venturi valve (2 of 4) There are two Venturi Valves mounted within each section of the Splicing Head. One valve is attached to each Vacuum Nip Bar, and one valve is attached to each Vacuum Splice Preparation Bar. When Vacuum is activated, the Vacuum Solenoid Valve is energized and air pressure is supplied to the appropriate venturi in the splice head to provide vacuum for the splice preparation. VACUUM Select SOLENOID valve The solenoid valve automatically directs the vacuum to the correct section of the Splicing Head (Upper or Lower) depending on which position is selected as the Running Roll. If the Upper Roll is the Running Roll, the Vacuum will be directed to the LOWER section of the Splicing Head, etc. When compressed air applied a Vacuum Venturi Valve, it creates suction at the port that is connected to a Nip Bar or Splice Preparation Bar. This suction is sufficient to hold the web in the Splicing Head. TO INCREASE THE HOLDING POWER ON THE WEB, THE FLOW CONTROLS SHOW ABOVE CAN BE OPENED AND ANY UNUSED VACUUM HOLES MAY BE COVERED BY TAPE. 31

32 When taping the unused holes on the Nip Bar Rubber, apply only one thickness of a light tape, such as Electrical Tape. Masking Tape should never be used. Replace the tape as needed. Do not apply multiple strips. Excess tape buildup, will reduce the sealing strength applied to the Splice Joint by causing uneven nip pressure. Register Splice This button allows the operator to select the splice in register feature. The splice joint is then made a preset distance back from the register mark on the print impression. This allows the operator to set up the new web in the correct place to keep the image in close registration during splice. Register Splice Graphic Use this Touch Switch to select the Register Splice Function of the SP1 Splicer. When the Green L.E.D. Indicator, at the Upper Left Corner, is ON, Register Splicing has been selected. When this L.E.D. is OFF, Splices will be made without regard to the Registration Marks on the web. The YELLOW L.E.D. Indicator, at the Lower Right corner, should FLASH, each time a Web Registration Mark is detected by the Registration Mark Sensor. SIDELAY CONTROL TOUCHSWITCHES Sidelay Select Graphic Each of the triangles in the Sidelay Graphic covers a Touch Switch. Use these switches to move the SP1 Splicer, across the unit centerline, to align the running web. Travel of the splicer is limited to approximately 1 Inch [25 mm] on either side of the centerline. If you attempt to go beyond the range of movement, a slip-clutch within the Sidelay Linear Actuator should prevent damage to the machine. Push on the arrow with the point that is facing in the direction that you want the web to move. 32

33 SYSTEM FAULT L.E.D. This L.E.D. is located in the lower left side of the operator panel just above the Butler Logo. This light signals a system fault with a red flashing light. SYSTEM FAULT (STATUS) L.E.D. The RED L.E.D., located above and to the left of the Butler Logo provides Information about the status of the splicer. IF THE FAULT INDICATOR IS OFF, THE MACHINE STATUS IS NORMAL. FAULT Indicator FLASHING. STATUS ALARM. The System Fault Indicator will be flashing ON/OFF at ½ Second Intervals, when an abnormal condition has been detected. At the same time, the indicator starts flashing, the Splicer is OK. Signal, to the Press/Process Line, will drop out. When the OK. Signal drops out, the line should stop. FAULT CONDITIONS A Fault is reported when: a). There is an alarm signal from the Roll Drive Motor Controller to the P.L.C. WHAT TO DO: CALL THE MAINTENANCE DEPARTMENT FOR ASSISTANCE. b). A Web Break has been detected. If the web breaks, the Dancer will drop to the bottom and the Dancer B Sensor will send a signal to the P.L.C. WHAT TO DO: RE-WEB THE SPLICER AND START AGAIN. c). The Dancer is near the top of its travel. The Dancer Empty Sensor will send a signal to the P.L.C. If the roll cannot turn easily, the web cannot unwind properly. The Dancer will be pulled up and the Dancer Empty Sensor will switch states. WHAT TO DO: CALL THE MAINTENANCE DEPARTMENT FOR ASSISTANCE. Reset The reset button permits the operator to reset the splicer for start up after an E-Stop, opening the interlocked electrical enclosure door, or a loss of power. E-Stop 33

34 The E-Stop button allows the operator to stop the machine in case of an emergency or urgent need to stop the process. To reset the E-Stop, you will need to pull out and turn the button, then press the reset button. Knife Release Pushbutton This pushbutton is used to retract a jammed knife into its home position so that it is ready for operation or maintenance. If the knife becomes dull, it can become jammed in the middle of its stroke. This pushbutton is used to retract the knife. The head should never be forced open. OPTIONAL CONTROLS. Core Splice This option uses a sensor on the roll drive to sense the color of the core. When the core is sensed, the splice is actuated and the web is backed up to the last register mark for an in register splice. The control switch can be toggled to either use standard diameter splice (OD- Outside Diameter) or core detect splice. This option is only capable of a maximum web speed of 170 fpm. 34

35 Splice- Core/OD End Tape Sense This option uses a sensor mounted after the splice head to detect a band of tape applied to the unwinding roll by the film/web manufacturer. The splicer activates the end of roll tape sense when the splice imminent diameter has been reached and then automatically activates the splice when the tape marker passes under the sensor. The control switch can be toggled to either use standard diameter splice (OD- Outside Diameter) or end of roll tape sense splice (end). Splice- END/OD 35

36 Auto Align This option uses a sensor on the machine output to automatically shift the machine laterally to keep the web tracking in the same position. A sensor is mounted on an adjustment handle as near to the splicer as practical. When the web moves out of alignment in the sensor, the splicer will shift in increments back into position. The sensor is a dead band sensor and it is capable of keeping web aligned within ±1/16. This option must be set up by a qualified technician, as proper function requires both pulse length and path delay to calibrated and entered. The control switch is an illuminated button (Illuminated is on). Flashing light indicates that alignment was not reached in the anticipated number of alignment pulses. Reset requires that the option is turned off. The web is verified for proper alignment manually, and the option is turned on again. Auto Align Remote Operator Panel/Sidelay The remote operator panel moves the splicer control to a remote panel which can be located on another piece of equipment. The machine is configured to be able to accept 24 VDC input signals to actuate the machine sidelay from a remote location. SPLICER STATES Ready: Shows that the splicer is ready for run and all systems are operating normally. Fault: Shows that the machine is in a fault state. ALARM / FAULT STATES: Drive Not Ready: Shows that the motor drive has a fault which must be corrected. Press Reset to clear. If it does not immediately clear, press E-Stop wait 20 seconds and then remove E-Stop and press reset. Dancer Empty: Signals that the accumulator is empty and has reached its top stop. To clear you need to raise the roll drive from the running roll and let enough paper unwind so that the dancer drops below the top of travel sensor. The lower the roll drive and press reset. The splicer will refill and be ready to run. Web Break : The web has broken, causing the dancer to drop to the bottom stops. Web up the machine and press reset to put the splicer back into the ready state. 36

37 E-STOP: The E-Stop button has been pressed triggering the E-Stop of the machine. Disengage the E-Stop switch and press reset. The splicer is then back in the ready state. Register Mark Fault : This fault shows that the splicer is not properly reading the register marks on the film when register splice has been selected. The splice ready light on the operator touch panel will now flash until the fault is corrected. If the fault is not corrected at autosplice diameter, the splicer will make a time out splice which will not be in register. The fault must be manually corrected (verify eye is correctly positioned, printed register marks are OK, eye is clean, or reset register eye) and then the splicer will automatically clear the fault. Splice not ready: This signals that the splice head is open or has not been opened at all and that the preset splice diameter has been reached. The splicer ready signal is removed causing the process to stop. The splice must now be prepared in the splice head and reset must be pressed. When the process is restarted an automatic splice will be made. 37

38 ROLL LOADING The SP-1 splicer is equipped with integral swing out shafts. The shafts are latched into position for running, and then when released swing out through the frame for easy loading from the front or side of the machine. Your splicer may be equipped with the optional LIFT AND LOAD System for the Upper Roll shaft, to allow the operator to lower the upper roll for loading nearer to the ground. DURING ROLL LOADING, BOTH ROLLS MUST BE INSTALLED SO THAT THEY UNWIND IN THE SAME DIRECTION. INITIAL ROLL LOADING/WEBUP SAFETY FIRST! THE ROLLS OF MATERIAL ARE HEAVY. USE SAFE LIFTING PROCEDURES AND EQUIPMENT TO AVOID BACK INJURIES. GET HELP IF NECESSARY. Position a new roll near the splicer. Any core plugs should be removed, at this time. Any outer wrappers may be slit, and left on the floor to protect the roll from damage. If the roll position is not clear, remove the old roll. For the roll to be removed, raise the Roll Drive Module. Pneumatic Roll Drive Lifters The Splicer is equipped with pneumatic cylinders that are used to lift the Roll Drive Modules. The pneumatic lift feature is standard on SP1 Splicers Upper Drive Lift Cylinder The figure shows the Upper Drive Module Cylinder in the extended condition. The Upper Drive Module has been lifted off the Upper Roll and it will stay in the lifted position as long as air pressure is applied to the bottom of the air cylinder. Each Lift Cylinder is controlled by its own manual, lever action valve, mounted on the Splicer side frame beside the splice head. 38

39 Roll Drive Lift Switches Roll Drive Lift Switches Drive Lift Switch/Valve (raise Module) Move the lever UP, to raise the Roll Drive Module. (With optional roll drive auto-engage, this function is controlled with switches on the control enclosure. See option) Drive Lift Switch/Valve (lower Module) Move the lever DOWN, to lower the Roll Drive Module. The roll drive will slowly descend to the roll when the switch is down as air is released through the drive flow control. (With optional roll drive auto-engage, this function is controlled with switches on the control enclosure. See option) 39

40 CAUTION! DO NOT ATTEMPT TO MOVE THE ROLLSHAFT UNLESS THE ROLL DRIVE MODULE IS UP. YOU COULD BE INJURED IF THE SHAFT WERE TO SWING OUT, UNEXPECTEDLY. Roll Shaft Latch To open the shaft position, the latch must be manually released. Grasp the end of the shaft and pull the shaft towards you. Let the latch will drop back down. ROLLSHAFT CLEAR Swing the Roll shaft out, to a convenient loading position. Remove the clamp from the free end of the shaft. Remove the Core Adapter from the free end of the shaft. Pull the core off the Roll shaft. It is very important to position the roll on the shaft correctly, so that the web position is the same from both unwind positions. Once the roll and shaft are in the splicer, the webs must be precisely aligned to each other during splice preparation. The entire splicer may be moved to align the running web to the Process Line. It is difficult to adjust a roll on a shaft when it is in the splicer. We include index marks on the roll shafts which should be used to have precise positioning alignment between the running roll and new roll. 40

41 These indexes are placed with Zero, on the Splicer Centerline and Index measurements going out from the center. There is an allowance included for the Roll Clamps and the flanges of the Roll Adapters. For example, if you install a roll and adjust the Roll shaft clamps so that the outside edge of each clamp lines up with the same number, the web will be in the center of the splicer when you place it on the Splicing Head Preparation Bar. CLAMPS & INDEX MARKS In the above example, each clamp is set at the 23.1 Index Mark. Roll shaft Indexes The roll is held in position by two clamp collars. These clamp collars uses an integral ratchet handle to tighten. Clamps and adapters 41

42 Removable roll clamps The rolls of material are secured with two clamps. The clamp closest to the Roll shaft pivot remains in place. The outside clamp is loosened by rotation the lever counter-clockwise. Pulling the lever away from the clamp and moving it to a new spot allows you to reposition the lever. The two clamps are used to hold the running roll and core adapters in place. CORE ADAPTERS (Typical) Install one of the appropriate adapters on the shaft and slide it up against the Inside clamp. Core adapter Remove the core adapter(s) from the core and be sure to insert them into the new roll. This part ensures proper performance of the splicer. Failure to use this part will lead to autosplice diameter faults and cause excess wear on the support shaft. The core adapter allows easy change between core sizes. 42

43 Pivot shaft out for unloading Remove outer clamp collar Remove butt roll and take out core adapters for reuse 43

44 Put inner core adapter on shaft and load new roll Add outer core adapter into roll core Install outer clamp With the new roll loaded onto the shaft, install the Outside Roll Clamp on the Roll shaft. 44

45 LIFT AND LOAD SYSTEM The LIFT AND LOAD System allows the operator to position the Upper Roll shaft at a reduced height, to improve the ergonomics of upper shaft loading. The LIFT AND LOAD System attaches the Upper Roll shaft to a pneumatic cylinder. When the Upper Roll shaft is clear of the Splicing Head, the cylinder allows the Upper Roll shaft to be lowered to a convenient height. Approximate Heights from floor. 18 Diameter Roll = 38. [457.2 mm Roll = mm]. 24 Diameter Roll = 42 ½. [609.6 mm Roll = mm]. LIFT AND LOAD ASSEMBLY The LIFT AND LOAD System is mounted on the outside of the splicer frame. The top of the lift cylinder is attached to the Roll shaft Pivot and it travels within a guide track. This system allows the upper roll to be brought down for easiest loading and roll positioning. 45

46 Lift and Load Control Switch/Valve LIFT AND LOAD control valve (A) A valve, similar to the one shown above, is used to control the LIFT AND LOAD cylinder. THE LIFT AND LOAD CONTROL VALVE MUST BE KEPT IN THE UP POSITION, EXCEPT WHEN CHANGING ROLLS AND THE SHAFT MUST BE LOWERED. IF THE CYLINDER IS NOT KEPT FULLY EXTENDED, THE ROLLSHAFT WILL NOT BE LEVEL, WHILE THE ROLL IS UNWINDING. To load a new roll, swing the Roll shaft out, and move the valve handle down. There are two Stops installed, as part of the system. 1. A Hexagon-Head bolt is inserted into the bottom of the Roll shaft. 2. A Roll pin is inserted into the Roll shaft Collar. 46

47 Roll shaft Stop (A) If the cylinder IS NOT fully extended (with air pressure applied) the stop will not clear the side frame of the splicer, when you try to swing the Roll shaft out. These features prevent an operator from improper use of this system which could lead to an unsafe condition. Roll shaft Stop (B) If the cylinder IS fully extended (with air pressure applied) the shaft stop will clear the side frame of the splicer, when you try to swing the Roll shaft out. Swing Stop With the control switch in the up position, swing the Roll shaft out, gently, to the swing stop. This stop is adjustable for best loading position. The control switch can then be lowered to lower the upper shaft into load position. 47

48 LIFT AND LOAD CONTROL VALVE (B) Move the valve handle, down, to lower the Roll shaft to loading height. Roll shaft up (A) 48

49 Roll shaft down Install the new roll on the shaft. Slide the new roll onto the Operator Side adapter. Slide the free end adapter onto the shaft. Insert the free end adapter into the core. Slide the free end clamp onto the shaft. Slide the free end clamp down the shaft, until the both clamps are against the adapters. There should be no visible space between the clamp(s) and the adapter(s). 49

50 Roll shaft Clamp with Handle The outer Roll shaft Clamp is secured by the use of a permanent handle. If you pull the handle up, you can rotate the handle without turning the clamp screw. This action is used to ratchet open the shaft clamp. WHEN YOU HAVE SECURED THE CLAMP, BE SURE TO POSITION THE HANDLE PARALLEL TO THE SIDE OF THE ROLL When the new roll is securely in position on the LIFT AND LOAD System, raise the Roll shaft. LIFT AND LOAD control valve (C) Move the valve switch UP, to raise the Roll shaft. 50

51 Roll shaft up (B) After the New Roll has been secured and the Roll shaft is in the raised position, swing the Roll shaft back into the splicer. As the Roll shaft approaches the Roll shaft support saddles, the shaft end will lift the Roll shaft latch. Roll shaft going in When the shaft is fully over the support saddle, the latch will drop down, to securely latch the Roll shaft into the run position. Roll shaft latched in position You may lower the Roll Drive Module, at this time, or, you may leave it up. For web up of the splicer the roll drive should be left in the up position. With the Roll Drive Module left in the up 51

52 position, it is easier to turn the roll to web up or bring the leading edge of the web to the splice head. After web up or splice preparation you must lower the roll drive to be ready for run or automatic splice. 52

53 WEB UP First E-stop should be pressed before web passage. The splicer must have the web passed through before it is ready for operation. To pass the web through the splicer, the future running roll must have its roll drive raised. The web is then unwound and passed through the splice head, through the register sensor and festoon clamp and finally the accumulator. The web must be pulled through the splicer per the web up diagram in the manual. It is critical to respect the exact web path for the splicer to function properly. When the web is passed out of the splicer, the roll drive is lowered and the Estop released and the splicer reset button is pressed to make the splicer ready to run. (the green light is illuminated on the operator panel roll position icon) The drive motor is now under power and the accumulator is automatically refilled. ATTENTION- VERIFY AFTER WEB UP THAT THE PROPER RUNNING ROLL IS SELECTED ON THE OPERATOR CONTROL PANEL UPON RESET LOADING THE NEW ROLL Open the shaft which corresponds with the non running roll. The outer shaft clamp must be released and removed. Remove the spent core from the shaft. Remove the core adapters from the spent core and place them into the new roll. Load a new roll onto the shaft. Push the roll entirely onto the shaft up against the collar stop. Place the outer shaft clamp in position and tighten it to hold the roll. Be careful to respect the correct direction of unwind for the new roll. Pass the web through to the splice head and thread the machine according to the following diagram. WEB-UP PATH A. Upper Roll Position. 2. Head Lead-Out Roller. a. Alternate Web Path. 3. Register Mark Sensor. B. Lower Roll Position. 4. Pre-Nip Bar & Gripper. b. Alternate Web Path. 5. Fixed Finger Rollers. 1. Splicing Head. 6. Dancer Rollers. (The number of Dancer Rollers and Fixed Finger Rollers may change, according to the speed specifications for each splicer). 53

54 WEBBING UP THE SPLICER When loading the rolls, ensure that the Registration Marks will be facing the Register Mark Sensor, as the web leaves the Splicing Head and in the correct orientation for the production process. Always refer to the web up diagram on the machine before web passage. After the roll has been loaded, bring the web through the Splicing Head. 1a b WEB PATH through Splicing Head (ILLUSTRATION ONLY, NOT TO SCALE). 1. Web Paths. 1a. Upper Web Path 1b. Lower Web Path. 2. Knife Cylinder. 3. Knife Cylinder. Holder. 4. Knife Holder. 5. Knife Anvil. 6. Nip Bar(s). 7. Register Mark Sensor. Pass the web through the Splicing Head. Then, thread the web according to the web up diagram. 54

55 Web Passage The web is passed through the splice head, then threaded through the accumulator. It is important that the indicated web path is respected for proper function of the splicer. SPLICER WEBBED UP When the splicer has been webbed up, the web will look like the web shown in Figure

56 GO TO RUN Once the splicer has been webbed up and the Drive Module has been lowered onto the roll, you are ready to go to RUN. Rotate the Emergency Stop Button CLOCKWISE, to release it. Push the RUN Button. Verify that the correct roll has been selected as the Running Roll. THE SPLICE CYCLE Splice action varies, depending on the method of Splice Initiation and if Register Splice has been selected. The standard splice cycle operates by receiving the splice actuation from a sensor or push button, decelerating the running roll to a stop, firing the nip into the web to seal the splice joint, cutting off the expired web from the splice, opening the splice head and reaccelerating the roll. During this cycle, the process is fed from the accumulator at the output of the splicer so the process does not need to slow down. There are a number of different ways for the splicer to react, when a request to make a splice is received. Following, is a list of some of the items that will affect the Splice Cycle. Operational Differences WEB RUNNING WEB STOPPED REGISTER SELECTED (ON) REGISTER NOT SELECTED (OFF) MANUAL SPLICE REQUEST AUTO-SPLICE (DIAMETER REACHED) AUTO-SPLICE (CORE DETECTED) AUTO-SPLICE (WEB WRAP DETECTED) SPLICE MODE VARIATIONS The sequence of operation of your splicer is effected by the mode of operation selected. A thorough review of splice cycle operations can be found in the maintenance section of this manual. SPLICE ACTUATION Your Splicer is equipped with a Roll Diameter Auto-Splice Sensor System. It may also have an optional splice actuation trigger system which can either have a Core Detector Auto-Splice Sensor System or a tape flag detector. There will be differences in the machine response, during an Auto-Splice, depending on the components in the system. 56

57 Auto-Splice by Roll Diameter Splice imminent & auto splice sensors The Standard SP1 Splicer uses an Auto Splice sensor that is triggered by seeing the presence of a metal rod, approaching the face of the sensor. These rods (Upper and Lower) are attached to the pivot shafts for the Roll Drive Modules. As the roll decreases in size, and the Roll Drive Module gets closer to the core, the rod swings in an arc. The sensor closest to the side frame is the Auto Splice Sensor. The second sensor is the Splice Imminent Sensor. The Splice Imminent Sensor is used to provide a Pre-Splice signal, so that the operator may verify the alignment of the running web, just before Auto-Splice. Rotating the rod on the Pivot Shaft and then adjusting the Flag which is described in the maintenance section adjusts the Trigger Points of the two sensors. 57

58 Splice Diameter Sensors The image shows the pivot shaft and attachment collar, the rod and the sensors. If there will be sufficient material left on the core, at splice time, the roll will be decelerated to a Look Speed. The Look Speed is a low speed that allows time for a Register Mark to be seen and reported to the computer to allow the roll to be stopped accurately for repeatable register splice accuracy. Then, the roll will be driven FORWARD, until the Register Mark Sensor sees a mark. As soon as the Register Mark Sensor sees a mark, the web will be stopped, the Web Nip will be closed and the Splicing Head will be actuated. 58

59 Core Splice This option uses a sensor on the roll drive to sense the color of the core. When the core is sensed, the splice is actuated and the web is backed up to the last register mark for an in register splice. The control switch can be toggled to either use standard diameter splice (OD- Outside Diameter) or core detect splice. This option is only capable of a maximum web speed of 170 fpm. Splice- Core/OD When the Roll Core Detector Auto Splice OPTION is used, the Sensor is activated when the Splice Imminent Sensor diameter is reached. Core Detector Auto-Splice Core Detector The Core Detector Auto Splice Sensor is shown in this image. When the sensor detects the color of the core, the roll is stopped and the Roll Drive Motor will reverse direction. The Roll Drive Motor will then go to the Look Speed. The Look Speed allows for repeatable detection and triggering of an in register splice. The expired roll is driven BACKWARD, until the Register Mark Sensor sees a mark. This direction change will wrap web around the core to prevent losing the web, off the core. As soon as the Register Mark Sensor sees a mark, the web will be stopped, the Web Nip will be closed and the Splicing Head will be actuated. 59

60 Splice Preparation The following information covers the steps needed to prepare a standard Butt Splice on the SP1 Splicer. In these pictures, the Lower roll is the Running Roll and the Upper Roll is the New Roll. New Roll in Upper Position. Load the New Roll If the Drive is down, raise it so the roll can turn freely. Drive UP Pull some web off the roll. 60

61 Web Ready Bring the web down, onto the open Splicing Head. Lead the web outside of the two Splicing Head Idler Rollers and onto the vacuum preparation bars. Pull enough web to reach past the Lower Section of the Splicing Head. Make sure to pull the web straight, and evenly from the new roll. NOTE! The roller closest to the Nip Bar is a pivot roller (the Compensator Roller) on springloaded mountings. At Splice Time, the spring-mounted roller will be allowed to move toward the Nip, as the Nip actuates. This movement provides the extra amount of web that is needed when the Nip Bar moves. The splicer is equipped with a Vacuum Select Solenoid Valve, it will automatically direct the vacuum to the correct section (Upper or Lower) of the Splicing Head. DO NOT OPEN THE SECTION OF THE SPLICING HEAD FOR THE RUNNING ROLL. PARTS OF THE HEAD MAY CAUSE A WEB BREAK, WHEN THE HEAD SECTION PIVOTS OPEN OR CAUSE DAMAGE TO SPLICE HEAD PARTS. Open the (Upper or Lower) section of the Splicing Head (opposite the running web half of the head) and place the web on the Nip Bar and Vacuum Plate. 61

62 SAFETY FIRST! USE CAUTION, WHENEVER A SECTION OF THE SPLICING HEAD IS OPENED. THE CUTTING KNIFE IS VERY SHARP CUTTING KNIFE (1 OF 2 BLADES) Under normal conditions, your fingers should not be anywhere near the Knife Blades. Upper Knife & Guard The machine has guards to protect the operator from the possibility of inadvertent contact with the Knife Blade. Operators must always use caution when in this area to avoid the knives. 62

63 Lower Knife & Guard Each guard is only effective when the Knife Holder is in the proper position. If there is a splicer fault which leads to the knife assembly getting stuck out of position, call maintenance and exercise extreme caution. Open the Splicing Head. When either section of the Splicing Head is opened, after a previous splice, the Vacuum will be automatically turned on. The Vacuum Select Solenoid Valve will apply the vacuum to the Non-Running Roll side of the splice head. 63

64 Splice Head Lock. The splice head is equipped with latches which are mechanically held clear of the non running side of the splice head so that the splice head is free to be opened on the non running side, but latched closed on the running side. If both sides are latched closed this indicates that the knife is stuck in the middle of its stroke. The knife home button should be pressed to retract the knife and then maintenance should be called to correct the cause of the fault condition. Vacuum Plate/Preparation Bar Each Vacuum Plate is equipped with a measuring scale, to assist you in aligning the side of the New Web to the side of the Running Web. The top edge of this plate is the reference point for preparing an exact butt splice. The web should be cut against this surface. 64

65 Web to Nip bar Now, put the web on the Vacuum Bar and the Nip Bar. The web must now be placed in precise registration for an In-Register Splice. Place the new web in the head. When a section of the Splicing Head is opened, after a previous splice, the Vacuum is turned on, automatically. If, for some reason, the vacuum does not turned on automatically, use the Manual Vacuum ON/OFF Pushbutton, on the control touch panel. (If vacuum is turned off, it must be turned back on manually) Pull the web taught and straight. Lay the web on the Nip Bar and the Vacuum Plate. The vacuum will hold the web in place. Use the Tape Measure affixed to the Vacuum Plate to ensure that the new web is aligned to the running web. Pull the web until your reference point is at the leading edge of the Prep Bar/Vacuum Plate. (The cutting guide will be the leading edge of the Preparation Bar). 65

66 Trim the web. Use a sharp blade to cut off the excess web. Place the blade against the edge of the Nip Bar and cut completely across the web. Cut Web Cut the leading edge of the splice joint and remove any scrap material from the Splicing Head Area. 66

67 Web trimmed When you trim the web, the remaining web will be held on the Vacuum Plate. The web should look as it is shown above. 67

68 TAPE APPLICATION The splicer has a tape dispenser mounted on it for operator convenience. The scale below the applicator uses the same index lengths found on the roll shaft and also splice head for easy set up and alignment. 2 [50 mm] wide, Single-Faced, Package Sealing Tape is often for Splice Joint. The best tape depends upon material to be spliced, temperature and other environmental issues. Butler Automatic carries special tapes if you have any difficulties with tape splices coming apart and failing. With the new web held on the Nip Bar and the Vacuum Plate, get a length of tape slightly less than the width of the web. For example, a 24 [60.9 cm] web would get a 23 [58.4 cm] length of tape approximately. Apply the Single-Faced Tape to the Silicone Rubber Covered Nip Bar, WITH THE ADHESIVE SIDE FACING OUT FROM THE WEB AND THE PREP BAR. Half of the tape will overhang the Leading Edge of the Incoming Web. The side of the Splicing Tape should be as close to the edge of the Nip Bar as you can place it, with no overhang. The tape should not overhang the sides of the web. Apply Splicing Tape Place the tape evenly on the Nip Bar. The vacuum will hold the tape. 68

69 Tape on Nip Bar The tape is no ready for web transfer. Slip the Web Grasp the edges of the new web, above the tape. Reposition the web Gently, slip the leading edge of the new web out, from under the tape. The Vacuum on the Preparation Bar will pull the tape in. You will now move the web to apply it onto the tape. 69

70 Apply the Web onto the Tape Pull the web to the same position that it was in when it was cut off. Place the leading edge of the new roll onto the Splicing Tape. Press the web down, to adhere the web onto the tape. At this point, the Splice Joint should look as in above figure. The Vacuum will hold the back of the tape on both the Preparation Bar, and the Nip Bar. The tape will hold the leading edge of the new web. Check the incoming web to make sure the edges are aligned to the running web. Adjust the new web, as needed, for proper alignment. In cases where the web has extreme curl, the attachment to the tape must be started in the middle and the web must be held off the tape, slowly pressing it down as you work your way outward on both sides. Slack the Web (a) Before you can close the Splicing Head, you must put some slack in the web, to prevent pulling the web back, as the head section rotates closed. 70

71 Head Closed With the web slack, rotate the open section of the Splicing Head to the closed position. Bring the head section fully closed. Verify that the splice joint has not been pulled back from it s proper position on the vacuum bars. Head Limit Switches When both sections of the Splicing Head are fully closed, these two limit switches will signal the P.L.C. that the Head is in the Safe & Ready condition. 71

72 Splice ready indicator The Splice Ready Indicator L.E.D. comes on when the splice is ready and indicates that the machine is ready for a splice cycle actuation. IN-REGISTER SPLICING Register SPLICE on/off Switch Verify that the Register Splice Switch is set correctly, for the type of splice, you will be making. The green light in the upper left corner of the selector button will illuminate green. The yellow light in the lower right corner flashes to indicate when a register mark is detected by the register sensor. REGISTER SWITCH SETTINGS OFF = Standard Splice (Register Mark Not Used). ON = In-Register Splicing enabled. 72

73 SETUP In-Register Splicing requires some initial setup of the splicer. If you will not be making an In-Register Splice, no precise placement of a Registration Mark is necessary. In order to trim the incoming web at the correct point, you must determine the distance between the Register Mark Sensor and the Splice Preparation Cut-off Guide in the Splicing Head. The register system has scales located along the register supports system. This scale indicates the distance from the register eye back to the cut point. The measure point for reference on the scale is the edge of the Delran register support closest to the splice head as read against the scale. When a register splice is made, the system slows down to a scan speed. When the register mark is seen, the web is stopped and the splice is made. Thus the running web is stopped with the register mark under the register sensor, and the new splice must be prepared to be in alignment with this position. Measurement X shows the distance back from the register eye where the splice will be made. The newly prepared web must be made in precise registration to the cut point. 73

74 MEASURE DISTANCE Measure distance to sensor A represents the aiming point for the Light Beam from the Register Mark Sensor. B is the edge of the Splicing Head Nip Bar. The Nip Bar has foam rubber glued to its face. C the Splicing Head Nip Bar. D is the Splicing Head Vacuum Plate. X represents the distance between Point A, and Point B. With the Splicing Head Sections in the CLOSED Position, set a ruler, scale, or measuring tape, in the Splicer. 74

75 Find distance X The measuring device should follow the Web path BACK, through the Splicing Head, The Leading Edge of the measuring device (or any reference mark) should be just at the edge of the Light Beam that is closest to the Splicing Head. Measure the distance from the edge of the Light Beam to the edge of the Nip Bar. Look into the Splicing Head and find position B. Look at the measuring device to determine the distance from point A. Write this measurement down. Distance X is shown on the scale located in the register splice adjustment. ALTERNATE METHOD REGISTER SPLICE SET UP When you make a splice the previously running web will be stopped in a specific place for register splice. Find the place on the image where the splicer stopped on this last splice, and then use that as the reference cut point for the set up of your register splices. This will make splice preparation in the correct place for register splice. 75

76 Sensor Bracket Assembly Positioning The Bi-Directional Sensor Bracket Assembly is mounted behind the Splicing Head. A. B D C B BI-DIRECTIONAL Sensor ASSEMBLY A. Festoon Area. B. Long Axis Adjusters. C. Cross-Web Adjuster. D. Splicing Head. ANYTIME A SENSOR IS MOVED, YOU SHOULD CHECK THE OPERATION OF THE SENSOR, IN THE NEW LOCATION. IF NECESSARY, REPEAT THE CALIBRATION PROCEDURE. See Maintenance section of this manual for sensor calibration. CROSS-WEB ADJUSTER (A) The block, that holds the Register Mark Sensor, can slide across the rods of the assembly. 76

77 CROSS-WEB ADJUSTER (B) The large black knob, on the side of the slider block, is used to lock the Sensor Holder Block in place. Loosen the knob and slide the sensor across the web until the light beam from the Register Mark Sensor is on a Register Mark. If the web is not transparent, you might have to use a mirror to see the mark. When the sensor light beam is in the correct position, secure the block by tightening the knob. LONG AXIS ADJUSTER lock Each of the two end blocks, have locking knobs that are used to lock the rods in place. To change the distance between the Register Mark Sensor and the Splicing Head, loosen both knobs and slide the rod assembly along the web. 77

78 LONG AXIS ADJUSTER Block (A) When the sensor is at the new location, push the Control Side Block against the support. LONG AXIS ADJUSTER Block (B) When the Control Side Block is against the support, the assembly will be at right angles to the direction of web travel. Any adjustments in the CROSS-WEB directions will be in a straight line. Lock the Control Side Block in position and then lock the block on the other side of the assembly. 78

79 WEB PATH THROUGH SENSOR ASSEMBLY Web path at sensor (A) This shows the web passing through the Register Mark Sensor Bracket Assembly. Note that the web passes OVER the first shaft (1), UNDER the middle shaft (2), and OVER the third shaft (3) Web path at sensor (b) 79

80 Web path at sensor (C) The figure shows the web path using the Bi-Directional Sensor Bracket Assembly. The image shows the web, as viewed from the Operator Side of the Splicer. The top three shafts of the assembly are used to modify the web path. With the web threaded as shown, web flutter is reduced. If the web were to go between the two rollers without any support, it may move up and down, away from the sensor. 80

81 INSTALLATION The splicer is a compact unit which is fully self contained and sits upon four adjustable feet. The weight of the machine is approximately 1100 lbs. The machine can be moved by a standard fork lift capable of carrying this weight. Please see electrical schematics for interconnection electrical and with the process. The machine is equipped with a pneumatic disconnect and must be connected to plant air. It is important that proper rigging equipment is used to move the equipment and that riggers with proper safety training are responsible for moving and erecting the machine. The machine is shipped with wooden shims under the front and back base laterals. These shims are required for moving the machine to avoid damage when lifting with forks under the base pate, but must be removed before operation for proper function upon installation. The machines have a hole in each side frame indicated with a shackle label. These holes are located at the approximate center of gravity of the machine and may be used for moving the machine. Warning: The base plate must be securely strapped to the machine cross laterals to avoid severe damage to sidelay motor assembly. The installation site must be fully prepared before the machine is brought into position. A centerline must be drawn on the ground where the splicer will be installed. With the machine in the middle of it s sidelay travel the idler rollers must be centered on this center line. The leveling feet of the machine are used to level the splicer. We recommend that level is made to within.003 per foot. The tram of the machine is also critical for proper web tracking. The tram must be within.003 per foot. The alignment tolerance is affected by material being run. It is very important that when installing this machine on older equipment that the entire web path is leveled and trammed for proper web tracking. It must be noted that the entire machine slides on its base. This requires that the electrical and pneumatic connections are made with flexible connectors. The splicer includes outputs to signal to the process that the machine is in the ready state for run. This signal and the E-stop signal must be connected to the process machine control. Remote sidelay is also available to respond to a 24 VDC input signal. Please refer to interconnection diagram for more details. We highly recommend that a Butler Technician inspect the machine installation before it is finally bolted to the floor. 81

82 SPLICER MAINTENANCE Before using this section of the manual it is critical to familiarize yourself with the safety warnings and directions at the beginning of the manual. We highly recommend using safety gloves when working near the cutting knife, and all lock out and other safety procedures must be followed when performing maintenance of any kind on this machine. Automatic Splice Actuation The SP1 Splicer uses an Auto Splice sensor that is triggered by seeing the presence of an adjustable rod with detector plate, approaching the face of the splice actuation sensor. These rods (Upper and Lower) are attached to the pivot shafts for the Roll Drive Modules. As the roll decreases in size, and the Roll Drive Module gets closer to the core, the rod swings in an arc. Standard Splice Actuation Sensors This image shows the pivot shaft and attachment collar, the rod and the sensors. The sensor closest to the side frame is the Auto Splice Sensor. The second sensor is the Splice Imminent Sensor. 82

83 Splice Imminent & auto splice sensors Rotating the rod on the Pivot Shaft and then adjusting the Flag above adjusts the Trigger Points of the two sensors. THE SPLICE CYCLE Splice action varies, depending on the method of Splice Initiation and if Register Splice has been selected. There are a number of different ways for the splicer to react, when a request to make a splice is received. Following, is a list of some of the items that will affect the Splice Cycle. Operational Differences WEB RUNNING WEB STOPPED REGISTER SELECTED (ON) REGISTER NOT SELECTED (OFF) MANUAL SPLICE REQUEST AUTO-SPLICE (DIAMETER REACHED) AUTO-SPLICE (CORE DETECTED) AUTO-SPLICE (WEB WRAP DETECTED) SPLICE MODE VARIATIONS Following are descriptions of the Splice Sequence of Operations, under various conditions. 1. MANUAL SPLICE: WEB STOPPED (Static Splice). IMMEDIATE SPLICE. Register Splice Switch OFF. OR: Register Splice Switch ON. Initiate (Push Touch Switch). Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. 2. MANUAL SPLICE: WEB RUNNING (Running Splice). IMMEDIATE SPLICE. Register Splice Switch OFF. Initiate (Push Switch). Decel (Stop Drive). Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Web Nip ( Pre-Nip ) actuates. Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. 83

84 3. MANUAL SPLICE: WEB RUNNING (Running Splice). IN-REGISTER SPLICE. Register Splice Switch ON. Initiate (Push Switch) DECEL (Drive slow Down). GO TO Look Speed. Find Register Mark. Stop Drive. Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Web Nip ( Pre-Nip ) actuates. Head actuates (Seals). CUT. Switch (Rolls and Controls). Vacuum Off. 4. AUTO-SPLICE (DIAMETER): WEB RUNNING (Running Splice) IMMEDIATE SPLICE. Register Splice Switch OFF. (The Auto-Splice Diameter will be preset by your technicians). Initiate (Diameter Sensor). DECEL (Drive Stop). Web stops. Zero-Speed Detect (W.l.F. Stop). Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. 5. AUTO-SPLICE (DIAMETER): WEB RUNNING (Running Splice) IN-REGISTER SPLICE. Register Splice Switch ON. (The Auto-Splice Diameter will be preset by your technicians). Initiate (Diameter Sensor). DECEL (Drive Slows). GO TO Look Speed. Find Registration Mark. Stop Drive. Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Web Nip ( Pre-Nip ) actuates. Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. Look Speed, is a low speed that allows time for a Register Mark to be detected and reported to the computer. 6. CORE DETECT AUTO-SPLICE: WEB RUNNING (Running Splice) IMMEDIATE SPLICE Register Splice Switch OFF. (Your technicians will adjust the Core Detector Sensors and their Amplifiers). Initiate (Core Detector Sensor). DECEL (Drive Slows). Stop Drive. Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. 7. CORE DETECT AUTO-SPLICE: WEB RUNNING (Running Splice) IN-REGISTER SPLICE. Register Splice Switch ON. (Your technicians will adjust the Core Detector Sensors and their Amplifiers). Initiate (Core Detector Sensor). DECEL (Drive Slows). STOP DRIVE. REVERSE DRIVE. GO TO Look Speed. Find Registration Mark. Stop Drive. Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Web Nip ( Pre-Nip ) actuates. Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. 8. WEB-WRAP SPLICE: WEB RUNNING (Running Splice). IMMEDIATE SPLICE Register Splice Switch OFF. (Your technicians will preset the Web Wrap Sensor). Initiate (Web Wrap Sensor). DECEL (Drive Slows). STOP DRIVE. Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Web Nip ( Pre-Nip ) actuates. Head actuates (Seals). Knife cuts web. 84

85 Switch (Rolls and Controls). Vacuum Off. 9. WEB-WRAP SPLICE: WEB RUNNING (Running Splice). IN-REGISTER SPLICE. Register Splice Switch ON. (Your technicians will preset the Web Wrap Sensor). Initiate (Web Wrap Sensor). DECEL (Drive Slows). STOP DRIVE. REVERSE DRIVE. GO TO Look Speed. Find Registration Mark. Stop Drive. Web stops. Detect Zero-Speed. (No W.l.F. Pulses). Head actuates (Seals). Knife cuts web. Switch (Rolls and Controls). Vacuum Off. ROLL CORE DETECTOR SYSTEM The Splice Imminent Signal is used to turn on the Core Detector Auto Splice System. When the Roll Core Detector System, Auto Splice OPTION is used, the Auto Splice Signal comes from a color Sensor that is attached to the roll drive and positioned to look at the roll surface. Auto Splice Sensors The Core Detector Auto Splice Sensor Assembly is attached to the roll drive. The entire assembly is adjustable for best focal angle. The sensor should be mounted ½ inch from the roll surface of a roll at core splice diameter. This distance may need to be altered slightly during set up if the sensor has difficulties distinguishing between any specific colors. This option includes a sensor on both the upper and lower roll drive. The Auto-Splice Sensor uses a White L.E.D. for a Light Source. The white light is directed at some nearby surface and the light is reflected back o a photodiode receiver in the sensor housing. The reflected light changes color, depending on the color of the surface that is reflecting the light from the sensor. Electronic color filters in the sensor can be adjusted so that only a certain color may cause the sensor to send out a signal. CORE DETECTOR SENSOR OPERATION 1. A white Light is projected from the sensor, onto the surface of the unwinding roll. While there is still some web on the core, the white light will not shine on the Kraft-Paper-colored Core. 2 The color of the light reflected from the WEB/Film does not match the color that the sensor has been adjusted to see. 85

86 3. When the last wrap of web is unwinding from the core, the core will be exposed to the white light from the sensor. 4. The color of the light reflected from the CORE matches the color that the sensor has been adjusted to see. When the correct color is recognized by the sensor, a signal is sent to the computer to initiate an Auto-Splice operation. If the colors of the cores change, you may have to recalibrate the sensor. While there is web on the core, the color of the reflected light beam will be the color of the web. Since the sensor has been calibrated to see only the color of the core, there will be no signal to the P.L.C. The end of the web is usually taped onto the core, with double-faced tape. When the last wrap of the web clears the core, the sensor no longer sees the Web-Colored reflected beam. The color of the reflected beam changes to the color of the core, and a signal will be sent to the P.L.C. When the P.L.C. gets the CORE signal, an Auto-Splice Sequence will be started. When used with the Register Splice OPTION, the Roll Drive Motor, upon splice actuation, the drive will reverse the direction of the unwinding roll at a slow scan speed. The web is rewound until a register mark is detected. The Roll Drive Motor will then stop, and the Splicing Head will be actuated. If the Register Splice OPTION is NOT used, the Roll Drive Motor will bring the unwinding roll to a stop, and the Splicing Head will be actuated. If the web is completely taped to the core, the core will continue to rotate, pulling the end of the web to the other side of the core and rewinding the web and the sensor will not detect the core. In effect, the web will wrap-up around the core. In this case the diameter splice option will need to be selected until properly wound rolls can be used. 86

87 Core Detect Sensor Information QC50 CORE DETECTOR SENSOR FEATURES Compact, self-contained design 87

88 Analyzes and compares color to color, or varying intensities of one color Fast 335-microsecond sensing response time Easy-to-set programming options for 1 2, or 3 colors Three programming parameters: channel, sensing mode, and tolerance level 10 tolerance levels to allow for product variation Output OFF-delay (6 options); selection applies to all three color channels Gated color detection option (also called inhibiting, synchronization or windowing) 4 LEDs plus 4-digit display show configuration and operating status Non-volatile memory for data retention 8-pin quick-disconnect with a 3-position swivel connector Choose models with either 3 NPN or 3 PNP outputs, one for each color channel OVERVIEW The true QC50 is an easy-to-use, compact true color sensor that uses modulated white light with red, green, and blue (R, C, B) electronic filters to scan for the presence of one, two or three colors. Its compact size allows it to be mounted almost anywhere. Configuration options include Programming mode for color detection parameters and Setup mode for selecting an adjustable output OFF-delay when needed. The sensor has three solid-state outputs that may be individually set for color differentiation or for color-plus-intensity differentiation (see Sensing Modes below). The sensor has two push buttons, Set and Select, plus a 4-digit LCD display, an Output LED, and three Output Status LEDs (one for each sensing output), for easy programming and status monitoring during operation. QC50 Color Sensor Features 88

89 SENSOR CONFIGURATION Outputs The QC50 can be programmed to sense one, two or three colors. Three outputs are available for this purpose. When a programmed color is sensed, the Yellow Output ( OUT ) indicator and the associated green Output Status LED turn ON, and the respective output conducts. The sensor is wired at the factory so all three channels may be used on different core colors. Sensing Modes The QC50 Color Sensor functions in one of two sensing modes: Color only (expressed as C on the 4-digit display) or Color-Plus-Intensity (expressed as C_I ). In Color sensing mode, only colors are sensed. This is most useful for sorting obvious color differences (for example red or black or green). The Color-Plus-Intensity option refines the sensors capabilities to include grayscale as well, broadening the spectrum of colors and shades, which the sensor can be programmed to detect. This feature allows batch sorting or identifying within a color family (foe example, light blue or medium blue or dark blue). The factory setting is C. Webs that have coloring similar to the core color may require C_I Mode. TOLERANCE LEVELS The Color Sensor can be configured to enable color detection at any of 10 levels of tolerance (0 to 9). The higher the number, the greater the level of tolerance, or range of acceptance, when the sensor attempts to detect a color. A tolerance level of 9 (expressed as tol9 on the 4-digit display) permits the sensor to accept a wider range of target conditions, compared to a tolerance level of 0 (expressed as tol0 on the 4- digit display) causes the sensor to discriminate more precisely and accept a narrower range or target conditions. The normal factory setting is 4. Run Mode Normal operation of the QC50 Color Sensor is called Run mode. The LED indicators and the 4-digit display indicate the sensor s current operational status. For Example, if the Color sensor is detecting the color for which output 1 is programmed, the indicators will appear: Output ( Out ) LED: ON yellow Output 1 Status LED: ON green 4-digit display: run Fig. 1. A quick guide to QC50 sensor programming 89

90 SENSOR PROGRAMMING Programming mode determines the colors the sensor will detect for each of the three outputs. Repeat the following steps for each output. Refer to Figure 84 for a quick overview of this process. SENSOR PROGRAMMING CHART NOTE: The sensor has a 12-second time-out. If a period longer than 12 seconds elapses between steps, sensor will return to Run mode without saving settings. SENSOR PROGRAMMING CHART * If the color being taught is out of the sensors range, a FAIL message will appear in the 4-digit display, followed by a Hi or Lo message (indicating too much or too little light, respectively). * *Remembering Settings: Save selected sensor settings by clicking the Set push button at the end of Programming mode. The settings are saved in the sensor s EEPROM memory and the sensor remembers the current settings, even after being powered off. REVIEW OF SETTINGS To review the sensor s settings, press Select for 2 seconds or more. The output channel, sensing mode, and tolerance level will then be displayed sequentially (see Figure 85), followed by the delay interval (applicable to all channels). At the end of the sequence, the display will indicate run or rund (depending on the delay setting). 90

91 91 - REVIEW SETTINGS Non-Initialization Display Messages When using a sensor for the first time, the message E2Pr may be displayed (see Figure 86). This indicates the memory has yet to be used. To correct this situation, set up a channel according to the procedure described earlier in Programming Mode. When any channel is set up successfully, a run or rund message is displayed. Channel non-initialization message and response

92 92 - END OF ROLL TAPE SENSOR OPTION Sensors behind Splicing Head A. Registration Mark Sensor. B. End of Roll Tape Sensor. End of Roll Tape Sensor (A) As an OPTION, your splicer may be equipped with an optical color contrast sensor. This sensor is located next to (or under) the Lead-Out roller for the Splicing Head. The sensor will either Look Up at the Web or Look Down at the web, as required. The mounting bracket allows for the sensor to be positioned at the correct location on either side of the web centerline. In this special application, the maker of the web will apply a distinctive piece of Marker Tape to the web, as it is being wound on the core. Placement of the tape will be at a defined distance from the end of the web.

93 93 - A B C Fig. 2. web simulation graphic A. End of Web taped onto core. B. Roll Core. C. Marker Tape. If the Auto-Splice Mode Selector Switch is set to END, the standard Auto-splice by Outside Diameter System will not function. Instead, the roll will continue unwinding until the End of Roll Tape Sensor sees the contrasting tape. Then, the Splice sequence will be initiated.

94 94 - AUTO-SPLICE MODE SELECTOR End of Roll Tape Sensor (B) The sensor is installed with the lens close to the web. SETUP: Unwind a roll normally and save the last few feet of web on the core, with the tape within reach. Install the core and web on the splicer and lead the web through the Splicing Head. Position the marker tape in front of the sensor lens. Keep tension on the web so that the correct distance from the sensor is maintained. Adjust the lateral position of the sensor, until the light beam from the sensor is showing on the Marker Tape. Sensor position clamp knobs Loosen the clamp knobs, move the sensor bracket and then secure the clamps Calibrate the End of Roll Tape Sensor.

95 95 - End of Roll Tape Sensor calibration Sensor Controls Control panel: The teach-in button can be locked against accidental actuation with run. In an undefined switching position, no teach-in procedure can be triggered. Light/dark-switching not required. Unit switches on the object to be detected, that was under the light spot during the first teach-in procedure (Marker Tape or standard web). Setting via push button: 1. Select TEACH, using the rotating switch. Controls, TEACH SELECTED 2. Position the Marker Tape under the light spot. Trigger first teach-in procedure via teach-in button. (Push and hold for more than 1 second). 3. Position the standard web under the light spot. Trigger second teach-in procedure via teach-in button.

96 96-4. Select RUN, using rotating switch. Controls, RUN SELECTED Acknowledgement: After the first teach-in procedure, the red transmission light flashes and the function signal slowly indicates that a second teach-in procedure must be triggered. -- LED and Q flash quickly = insufficient contrast. -- LED and Q do not flash = teach-in completed. SIDELAY CONTROL To adjust the alignment of the web, as it goes into the process line, the splicer may be moved (sidelayed) on its base. For a full explanation of Manual Sidelay Control, please see the SP1 Operators Manual. A Single-Phase, Reversible Direction A.C. Motor, is used to drive a ball screw, within a Linear Actuator, SIDELAY LINEAR ACTUATOR Sidelay Travel is approximately 1 Inch [25mm] to either side of the unit centerline.

97 97 - Manual Control of the Sidelay Actuator comes from the Directional Control Arrow Membrane Switches, at the bottom of the Operators Control Panel. SIDELAY CONTROL SWITCHES AUTO ALIGNER SIDELAY (Sensor) The alignment Sensor is located at the edge of the web, after the web exits from the SP1 Splicer. It is important that he sensor is mounted as close to the splicer output roller as possible. This allows for a minimum path delay and fastest alignment response. SENSOR AND ADJUSTER ASSEMBLY The sensor contains a pair of Retro-Reflective, Infra-Red Photocells. The entire assembly has two machined holes so that it can be mounted to the nearest surface at the output of the splicer. The letters F for Front and R for Rear, on the face of the sensor identify the two Photo-Eyes. The sensor assembly is mounted on a slide screw for lateral adjustment. The aligner sensors control the splicer sidelay when the auto align feature is activated. When the sensor is moved sideways, the entire splicer will respond with side movements to bring the web into alignment with the sensor. Thus the sensor position becomes the controlling element for web position.

98 98 - SENSOR When the web is in front of an eye, the reflected light beam is detected by the eye EXAMPLE OF ALIGNER OPERATION. If the web were to move to the LEFT, BOTH the F and R sensors would see their reflected light beams. The Splicer Controller would recognize this condition and the Splicer Sidelay Motor (Linear Actuator) would be turned on to move the Splicer and output web to the RIGHT, to correct the web position. The splicer will move in discrete increments of approximately 1/30 th inch. The aligner will pulse one increment, wait for the programmed path delay to see if the web reaches the proper position, then repeat another pulse until alignment is reached. The Sensor and its Adjustment Arm should be attached to a part of the Press/Process line that does not move when the Splicer Sidelay is used. The web must first pass over the Eye marked F and then over the Eye marked R. SET FOR REDUCED WEB MOVEMENT. The sensor Dead band range is to 0.50 [1.5 mm to 13mm]. To increase or decrease the dead band before adjustment the sensor is loosened and the two halves are moved to either create a large or smaller offset between the two sensors in the assembly. During the installation of the splicer, the program must be updated to adjust the sidelay increment for accurate response per increment and input the path delay to have the correct wait period before the next pulse is made (so sensor will not hunt back and forth). Once the Web Position has been established and the sensor has been place correctly, push the AUTO ALIGN Button to turn the Automatic Alignment System ON.

99 99 - AUTO-ALIGN PUSHBUTTON When Auto-Align ON has been selected, the Indicator Light in the pushbutton will come ON to confirm the selection. At this point, anytime the web moves out of position, a correction will be made, by moving the splicer, to bring the web back, into alignment. The Splicer Sidelay Linear Actuator is mechanically limited to approximately 2 [50 mm] of travel. When the actuator tube has been fully retracted (or fully extended) an Internal Slip-Clutch will prevent damage to the actuator motor. During Manual Sidelay Operation, the Splicer Operator would not keep the Sidelay Linear Actuator Motor running, for long periods resulting in an overload trip. During Automatic Sidelay Operation the system will go into a conflict mode after 20 attempted adjustments to avoid any damage to machine components. The auto align selector light will flash for indication of this fault. The operator should then verify web position, check and correct sensor position, and turn the option off and then on again.

100 100 - OTHER OPTIONS- ALERT INDICATORS CONTROL CABINET In addition to the Splicer Controls, your SP1 Splicer could be equipped with additional indicators.

101 101 - CONTROL CABINET A light tower can be attached to the top of the Controls Cabinet. The standard light stack is equipped with three lights with red yellow and green to indicate the various splicer states. INTERFACE OPTIONS The Butler SP1 Splicer can supply information to or collect information from, the process line control system. Your Maintenance Department will be advised of the available options that are installed on your splicer. SPLICE HEAD Nip bar replacement

102 102 - Unscrew the two outside nylstop M4 fasteners. Remove the air connected to the bar. Remove the nip bar and replace. Replace the pneumatic (vacuum) tube. Screw back in the two fasteners. After fully fastening the screws, back them out 1/3 turn to leave some play in the system to avoid mechanical binding. Replacing The Cut Knife ATTENTION! KNIFE BLADES ARE EXTREMELY SHARP. TAKE PARTICULAR CARE NEAR THE KNIFE AND WEAR GLOVES OR PROTECTION. The knife blades should not be replaced while the knife assembly is inside the splicing head. Butler Automatic recommends an extra knife holder assembly for knife replacement. knife holder (Ref. Butler # L ) the existing holder can be reused by replacing the worn blades with new blades. blades (Ref. Butler # A ) These knives must be installed on the holder so that the blade edge just comes back over the support anvil. The knife holder is then ready for an easy replacement if the knives should be worn again.

103 Instructions for Replacement of Knife Holder assembly Splice Head Cut all electric and pneumatic power to the machine. Lock out tag out the splicer before you attempt any service on the splice head. Verify that no stored energy is in the pneumatic circuit. Knife holder in removal position The knife holder must be at one or the other side of the cylinder stroke. Open the two halves of the splice head. Open the upper half of the splice head 103

104 104 - Move the knife holder. Move the knife holder to the middle of the splice head to gain more room to work on the device. Remove pneumatic tubing By depressing the collar, the air line can be removed from the fitting. Remove outside large diameter screw on each side of the knife cut cylinder. Pneumatic disconnections (2). There are two pneumatic connections on the knife cyclinder which must be disconnected. (One on each end of the cylinder) Knife cylinder support screws Do not change the adjustment of the screws on the front of the knife cylinder support. These are factory set and should not need adjustment.

105 105 - Accentric adjustment. An accentric is used to align each end of the knife cylinder. This is a factory setting. Knife holder on anvil/guide. Knife Cylinder and support Remove the knife cylinder and support and place on a bench. Remove Screws. Remove the two large screws. If you need to remove the knife cylinder and support, examine the knife holder assembly. This should normally remain in the splice head on the anvil/guide bar. Make sure that during this operation that the knife holder remains in the splice head and does not fall onto the floor. Knife Holder If necessary replace the entire knife holder assembly as a unit

106 Knife Cylinder Replacement REINSTALLATION Knife Cylinder with support. The Knife cylinder is supported by a set of plastic supports and a rubber strip inside the support. Install the Cylinder inside the support. Slide the new cylinder with the pneumatic fittings installed in its support. Take care not to damage the plastic strips and rubber supports while replacing the cylinder. Reinstallation of cylinder. Reinstall the knife support, the knife cylinder, and knife holder. Move the knife cylinder and support to align the cylinder with the knife and reattach. Cylinder Slide Screws. Remove the two screws from the cylinder slide from the old cylinder. Install these screws on the new cylinder. Reinstall screws Install the two large screws to the knife cylinder support. Replace the pneuamtic pipes. Test the pneumatic connection by pulling gently on the tube into the fitting. The tube must remain firmly in place. Restore pneumatic pressure to the machine. Restore electricity. 106

107 Replacement of Cut Knives ATTENTION! THE KNIFE BLADES ARE EXTREMELY SHARP. TAKE EVERY POSSIBLE PRECAUTION WHEN WORKING WITH OR AROUND THE KNIFE. The cut knives (2) (Ref. Butler # A ) are fixed on a rotating pivot (Ref. Butler # B ) by four screws.under each pivot is a rotary spring (Ref. Butler # A ). Rotary Pivot aligned. Gently turn the pivot counter clockwise until it is in the proper alignment. Knife support with two knives Gently unscrew the four knife screws. Gently slide out the knife and remove from assembly. Repalce Knife. Slide the new knife into the screws attached to the pivot. The knife must be facing left. Always leave clearance between the back of the knife and the knife holder. To verify knife position use a 10 mm X 10 mm bar. The sharp edge of the knife must come down just past the edge of this square bar. Rotary Pivot. When the knife is removed from the assembly, the pivot will turn approximately 90 degrees. When reinstalling the new knives, the pivots must be first turn back to position. 107

108 Replacing the knife pivot spring. There is a torsion spring attached to each knife pivot. The torsion spring is located under each knife pivot. The torsion spring (Ref. Butler # A064523) is centered under the rotary pivot ( Ref. Butler # B064485). The V groove of the knife must pass the square bar, and the top of the knife must pass the bar by 6-7 mm. Tightening screws. For the correct attachment of the knives, the screws must be properly tightened. Knife Holder If the spring must be changed, first remove and restock the knife. Unscrew the screw holding the pivot from the opposite side of the assembly. Do not lose the washer. Remove the rotary pivot. The torsion spring sits around the rotary pivot and each end of the pivot is inserted into a 1 mm hole, one side on the pivot and one side on the knife holder assembly. Verify the rotation of the knife. The knife must easily pivot and return to cut position. After replacing and checking both knives, the assembly is ready to go into stock. Knife Holder Assembly. Identification. A Representation of Rotary Pivot B Representation of Rotary Pivot 1 Rotary Pivot 2 Upper end of Spring 3 Center of Rotary Pivot 4 Lower end of Spring 108

109 SPLICING HEAD PIVOT SECTION ALIGNMENT The two pivoting sections of the splicing head contain the Splicing Head Nip Bars. If these two bars are not parallel to each other, the Splice Joint will not seal properly and it may come apart. Each of the four, Black, handles for the pivoting section, has a socket-head setscrew installed in the shaft for the handle. Handle & setscrew (A) These setscrews are used to adjust the closed position of the Head Sections. Handle & setscrew (b) Once the screw has been adjusted, a stop-nut is used to lock the screw in place. 109

110 Side plates By aligning the side plate of the Pivot Section to the side plate of the Head, the parallelism of the Nip Bars is assured. Use an Adjustable Square to check the position of the Pivot Section. TEST 1 Place the body of the square against the Head Side Plate and move the blade until it touches the side plate of the Pivot Section. The actual distance is not critical. 110

111 TEST 2 Move the square down and place the body of the square against the Head Side Plate. Make sure that the fit at the top and at the bottom are the same. Adjust the Socket Head Setscrews until the fit is the same at the top and bottom of each of the four side plates of the Pivot Sections. Lock the setscrews. Pneumatic Manifold Splicer splice head cylinders are controlled pneumatically by use of a pneumatic manifold. The manifold is mounted on the machine frame and is wired to splicer interface circuit board via 25 pin D-Sub connector and cable. Manifold and cable are suitable for use in non caustic wash down environment rated for IP56 or IP65 depending on the wash down option selected. REGISTER SENSOR INFORMATION Register Mark Sensor Location The Register Mark Sensor is located on a bar, between the Splicing Head and the Web Nip Bar. The sensor is a retro-reflective photocell sensor, with a visible (red) beam of light. 111

112 Installed sensor. SENSOR GAP Place a length of precision key stock or a stack of feeler gauges equal to 0.50 [12.7mm] on the adjacent idler roller and adjust the vertical spacing from the lens to the roller. SENSOR ANGLE The Register Mark Sensor is installed at an angle of 15 to the web. The holes for the mounting screws that go through the sensor are offset to provide the correct angle. Lateral adjustment (across the web) may be obtained by loosening the two large black knobs in the mounting block. Install the web in the splicer. Adjust the side position of the web, as needed for the correct running position. Move the beam of the sensor to a position where the red light is centered on a Registration Mark. Tighten the two large black knobs in the mounting block, to maintain the position of the sensor. The lens of the sensor must be cleaned occasionally. Use a clean, soft cloth. Do not use any solvents around the sensor. Check the operation of the sensor regularly. The Register Mark Sensor has Yellow L.E.D. on the control end. The Yellow L.E.D. should flash, whenever the sensor sees a Register Mark passing by the light beam. INPUT L.E.D. # 0.1 on the C.P.U. should be on whenever the Yellow L.E.D. on the Register Mark Sensor is on. SENSOR PROGRAMMING SENSOR END VIEW. In this view, the Teach In Button is above the YELLOW L.E.D., on the right end. Position a Registration Mark, on the roller, in front of the light beam. 112

113 Click the Teach-In button on the end of the sensor. The red sender light and the Yellow L.E.D. will blink slowly. Move the web so that the Registration Mark is NOT in front of the light beam. Click the Teach-In button. The Yellow L.E.D. will turn off. Verify the operation of the sensor by alternating a Register Mark and a blank space, under the light beam. The Yellow L.E.D. should flash, whenever the sensor sees a Register Mark. CALIBRATION OF REGISTER SENSOR An LED on the register button can be used as a reference to see that the register sensor is working properly. In the case that recalibration is required, use the following procedure: - Move the web with register mark near the register eye within the 10 mm detection range. - Move the register mark under the register eye and press the button until the LED on the sensor starts to flash. - Move the sensor eye over the web background and press on the setting button on the eye again. The following is a more detailed explanation of this system set up. Loosen the knobs to slide the sensor bracket across the web. It may be necessary to relocate the Sensor Cable. Always make sure that the Sensor Cable is not in a position to touch the web or any rollers. Apply tension to the web to keep it straight. Adjust the sensor position, to center the light beam on a Register Mark. Move the web to shift the Register Mark light beam on and off the target. You must have the Yellow LED ON STEADY, whenever a Register Mark is seen by the sensor. TEACH THE REGISTER MARK SENSOR. The sensor contains a transmitter for a beam of light and a receiver for a reflected beam. Whenever the product is changed, the Register Mark Sensor must be checked to ensure that the Register Marks can be recognized. The sensor may have to be reset for different contrast Register Marks. If necessary, complete the following steps. When you are finished, you must have the Yellow LED ON STEADY, whenever a Register Mark is seen by the sensor. Register Mark Sensor NOTE! The color of the light beam is automatically selected by the sensor, during the set-up Teach operation that follows. 113

114 The sensor will automatically select between a Red, White, Blue, or Green colored beam, according to the color and density contrast between the body of the web and the color of the Registration Mark. Register mark Sensor Parts A. Transmitter B. Receiver. C. Teach In Button. D. Status Indicator L.E.D. 1. Position a Register Mark with the Beam of Light on the mark. 2. Press the Teach-In button and release it. The RED Sender Light and the Status Indicator L.E.D. should blink slowly. 3. Move the Register Mark so that the Beam of Light is NOT on the mark. 4. Press the Teach-In button and release it. The RED Sender Light should come ON, steady. 5. Move a Register Mark back and forth, opposite the Beam of Light. The Status Indicator L.E.D. should come on, at each mark. 6. Whenever the Status Indicator on the sensor flashes, the indicator on the Register Splice Graphic (on the Operators Panel) should also flash. 114

115 Register Splice Graphic 7. The YELLOW L.E.D. Indicator, at the Lower Right corner, should FLASH, each time a Web Registration Mark is detected by the Registration Mark Sensor. REGISTER SPLICE TOUCH SWITCH AND Indicator Lamps (A) The GREEN L.E.D. in Upper Left Corner verifies the status of the Register Splice Option. ON = In-Register Splicing selected. OFF = In-Register Splicing NOT selected. STATUS 1, NORMAL, ON or OFF. When a SPLICE command is recognized, with In-Register Splicing selected, the P.L.C. will Look for a Registration Mark on the web, before stopping the web and firing the Splicing Head. When a SPLICE command is recognized, with In-Register Splicing NOT selected, the P.L.C. will decelerate the Running Roll to a stop, and actuate the Splicing Head, without regard to the position of any Registration Marks on the web. STATUS 2, ALARM STATE. If the GREEN Register Splice ON/OFF Indicator Light is flashing at Equal Intervals, the status has changed. This equal interval flash shows that the Registration Mark Sensor has not found a continuous group of Registration Marks. Missed marks could be due to a number of causes. Check position of the sensor to the marks. Clean the lens. Teach the sensor again. Have the Maintenance Department to check the operation of the sensor and the P.L.C. CONDITIONS: a). Register Splicing must be selected ON. b). The web must be running at a speed greater than 25% of normal speed. c). Registration Marks must be missed for two minutes. Unless conditions are corrected, the roll will run down and an Automatic Splice will be initiated at the pre-set diameter. The Registration Marks will not be used to position the Splice Joint. 115

116 REGISTER SPLICE TOUCH SWITCH AND Indicator Lamps (B) The YELLOW Register Mark Confirmation Sensor L.E.D. in the Lower Right Corner will be triggered, for a short duration, when Register Marks are being seen. In order to make this confirmation of the Registration Marks; 1. The Sensor must be positioned correctly, so that the Light Beam strikes the web, on the Registration Marks. Move the Sensor, as needed. 2. The sensor must be clean and operating correctly. 3. The web must be unwinding and correctly oriented. 4. The Register Splice Selector Switch must be set to ON. If you were to attempt to make an In-Register Splice without seeing any Web Registration Marks, you will make a splice, but it will not be In-Register. At Splice Time, the computer will be looking for a Registration Mark before firing the Splicing Head. The Splice Cycle will stay in slow-speed mode while it looks for a mark. The Dancer will be drawn up, until the system is shut down or times out to fire the splice. 116

117 WEB PATH THROUGH SENSOR ASSEMBLY Web path at sensor (A) This figure shows the web passing through the Register Mark Sensor Bracket Assembly. Note that the web passes OVER the first shaft (1), UNDER the middle shaft (2), and OVER the third shaft (3). Web path at sensor (b) Web path at sensor (C) This figure shows the modified web path, when using the Bi-Directional Sensor Bracket Assembly. The graphic shows the web, as viewed from the Operator Side of the Splicer. 117

118 The top three shafts of the assembly are used to modify the web path. With the web threaded as shown above so that web flutter is reduced. If the web were to go between the two rollers without any support, it may move up and down, away from the 118

119 Dancer Adjustment. The dancer rollers must always remain parallel with the fixed top rollers. If a web jam or web break causes misalignment in the dancer, a level must be used to restore the level by adjusting the connection of the dancer support belts to the movable dancer system. The dancer level can be adjusted by loosening the two connection bolts to the Delran belt connection and adjusting them up or down as needed. The dancer drive belts can also be tightened if required, using the tightener at the bottom of the belt course. The lower drive belt sprocket is attached to a pivot bar which acts as a tightening device. See sensor adjustment section later in the section for information on dancer sensor adjustment. 119

120 DRIVE SYSTEM SERVICE Roll Drive Direction Change. Roll Drive Belt Reversal. Roll Drive Belt Replacement. Roll Drive Bearing Replacement. NOTE! THE ROLL DRIVE MAY BE SERVICED, EITHER ON THE SPLICER OR ON A WORKBENCH, AS YOU PREFER. This section covers the servicing of the mechanical components of the Roll Drive System. In addition to information on bearing and belt replacement, this section may be used if the rotation of the Roll Drive System must be reversed. NOTE! There are variations in the mounting of the Roll Drive Module, (Surface Drive Assembly) depending on the size of the rolls that will be running on the splicer. In some versions, the part that attaches to the Pivot Shaft is integral to the Main Casting of the Roll Drive Module. In some cases, the Pivot Arm and the Roll Drive Module are separate parts that are bolted together. They may be taken apart, leaving the Pivot Arm on the Pivot Shaft. Please review the next few pages and decide what the best method is, for servicing your splicer. The two Roll Drive Modules are arranged to unwind the webs in the standard direction for that application as specified with the order. If a change in unwind direction is required, it can be done by your maintenance department. NOTE! IF THE ROTATION OF THE MOTORS IS CHANGED, THE DRIVE BELTS MUST BE REVERSED. THE BELTS MUST DRIVE IN THE DIRECTION OF THE ARROW ON THE BELT, AT ALL TIMES. WRONG DIRECTION WILL SIGNIFICANTLY SHORTEN THEIR LIFE EXPECTANCY ARROW ON BELT At the time the splicer was assembled, there was a visible arrow on the Drive Belt. Over time, the markings might wear away. BEFORE YOU SERVICE THE MODULE, MARK THE BELT ROTATION. If the belt is not driving in the direction of the arrow, it could fail at the splice joint in the belt. Before performing ANY service on the Drive System: 1. Remove the web from the Festoon. 2. Remove the Rolls and Roll shafts from the Splicer. 3. Lower the Drive Roll Modules to the limits of their Cylinder Travel. 4. Turn off and Lock Out the Compressed Air Supply and the Electrical Power for the Splicer. DRIVE MOTOR REMOVAL 120

121 Cut wire ties Cut any wire ties that are used to hold the motor power cable on the arm and on the Drive Module. With the wire ties cut, the Upper Motor should be able to be placed on the plate over the Dancer. The Lower Motor should be able to be placed on the base of the splicer. Remove bolts The drive motor is a hollow shaft gear motor. The drive is supported by a flange mount to the drive casting. Remove the four locking nuts which secure the motor. Four set screws remain in the casting to secure the flange and spacer. These set screws are lock tighted into place for ease of assembly and disassembly. 121

122 Remove the Motor (A). A. TWO Keys. With the bolt removed, slide the motor off the pulley shaft. NOTE! BE CAREFUL NOT TO LOSE THE TWO KEYS FOR THE PULLEY SHAFT. Store the keys in a safe place, to prevent loss or damage. CAUTION! THE MOTOR ASSEMBLY WEIGHS APPROXIMATELY 19 POUNDS [8.6 KG.]. Remove the Motor (B). Place the motor in a safe and secure location. For added safety, you should tie the motor in place. 122

123 Install keys & motor Install the two keys in the drive shaft keyway. If needed, pull on the belt to rotate the drive shaft to place the keyway on the top. Align the keys with the keyway in the motor sleeve and slide the motor onto the drive shaft. Remove mounting bolts OPTIONAL: Remove the bolts that are holding the Drive Module onto the Pivot. Remove the Roll Drive Module from the Splicer. 123

124 MODULE ON BENCH. OPTIONAL: Place the Drive module on a workbench. Drive module disassembly Without the weight of the motor on the driveshaft, you may disassemble the Drive Module. Remove the SIDE PLATE screws Remove the three Hex-Head bolts that hold the side plate to the main casting. Store the bolts in a safe place, to prevent loss or damage. 124

125 Bolts removed With the bolts removed, the side plate may be removed. Side plate coming off The main casting and the side plate hold the bearings for the shafts, in precise alignment. The bearings are pressed onto the shafts and are a slip-fit into the bearing housings in the main casting and the side plate. If the side plate cannot be removed by hand, it may be necessary to pry it away from the main casting. NOTE! USE CAUTION WHEN APPLYING FORCE TO THE PARTS OF THE DRIVE MODULE. DO NOT DAMAGE THE BELT. DO NOT DAMAGE THE PULLEY FLANGES. DO NOT DAMAGE THE CASTINGS. 125

126 Remove side plate The side plate will come off and leave the three shafts and their bearings in place. However, one, or more of the shaft and bearing sets may come out with the side cover. Be prepared to recover any parts that may be dropped. The side plate will be held by the alignment dowel pins at each end of the casting. It is recommended that the pulleys are pushed fully back before removal of the side plate. NOTE! AS YOU DISASSEMBLE THE ROLL DRIVE MODULE, MAKE NOTES ON WHAT PART WAS USED IN WHAT LOCATION. THE 30 MACHINE USES SPACERS IN THE DRIVE BEARING SEATS. RETURN THE MODULE TO THE SAME CONFIGURATION ON ASSEMBLY. BELT REMOVAL The drive belt is made with special plies and fibers, to resist stretching. It is covered with Linatex which is a food grade covering commonly used in form fill seal applications to drive the web. These belts have a long life, but will need periodic inspection and replacement upon signs of wear. Belt Removal (A) The belt is held in the unit by the flanges on the pulleys. There is no significant tension on the belt. 126

127 Belt Removal (b). Remove one of the Idler Pulleys by pulling the assembly out of the Bearing Socket. This will free the belt, for removal. BELT REMOVAL (C). BELT REMOVAL (D). The Drive Belt may now be replaced or reversed. While the pulleys are accessible, check the security of the set-screws. The set-screws must be tightened against the flats on the shafts. 127

128 BELT direction arrow The arrow on the belt indicates the direction that the belt MUST travel, during operation. If the roll unwind direction is reversed, by changing the motor rotation, the belt MUST also be reversed. If the bearings must be replaced, continue into the next section. If not, re-assemble the Roll Drive Module. BELT Replacement (A) Install the belt, with the arrow facing in the correct direction. Replace the pulley which was removed. BELT Replacement (A) Replace casting side plate by sliding it onto dowel pins. Press the casting closed. 128

129 Secure Casting Tighten bolts to secure casting cover side plate. Drive Module ready Restore the electrical power and air pressure to the splicer and resume normal operation. BEARING REPLACEMENT With the belt removed, by following the previous instructions, you may replace the bearings. If the drive Belts are in good condition and you only need to replace bearings, they may be replaced now. Bearings should always be replaced in sets of two per shaft. Replacing a single bearing on a shaft may result in more work, in the long run. All six bearings, within the Roll Drive Module are identical. There are two short shafts for the Idler Pulleys and a longer shaft for the Driving Pulley. Assembly of the bearings onto the shafts follows the same procedures for both the Idler Shafts and the Driving Shaft. 129

130 Electrical Enclosure. Any work on the electrical systems of this machine must only be performed by trained and qualified personnel, taking all precautions to avoid injury or damage to the machine. If any qualified personnel modify the equipment to perform a functional test, proper precautions must be taken and the machine must be returned to original state immediately after. Refer to the electrical schematics and program listing. The electrical enclosure contains: - A Frequency controller for control of the drive motor- roll is driven at a varying speed to control dancer position. - A PLC to control the functions of the machine and different cycles of operation. - A 24 volt power supply feeding power to the relays and controls required for machine functions. Electrical Adjustments Splicer Interface Circuit Board Butler Automatic has designed an interface circuit board for use in SP1 product line. Splicer interface circuit board was designed to accommodate additional non-standard circuits while allowing for one custom stainless steel electrical enclosure. This circuit board is hard wired to machine control PLC and to operator touch panel that is mounted on the electrical enclosure. See section on operator touch panel for operation and description of this panel. The circuitry of the interface board is shown on the SP1 electrical schematics. 130

131 Calibrations & Troubleshooting The PLC has output and input LEDs which can be used to help troubleshoot any problem with splicer operation. Refer to schematics and other electrical drawings for more information. Wiring Diagram Excerpt A (PNP) Wiring Diagram Excerpt B (PNP) 131

132 PLC 24BWA W.O.F. I:0/0 A U X. I N A U X. O U T A N A L O G Allen Bradley P.L.C. (pnp) Layout L.E.D.s for OUTPUTS O 0.0 O 0.7 L.E.D.s for OUTPUTS O 1.0 O 1.1 W.O.F. I 0.0 L.E.D.s for INPUTS I 0.0 I 0.7 L.E.D.s for INPUTS I 1.0 I 1.5 Siemens P.L.C. Layout 132

133 The SP-1 uses PNP Central Processing Units from either Siemens or Allen Bradley for the P.L.C. computers and associated sensor inputs. W.I.F. & W.O.F. Sensors NOTE! In some of the following text and figures, mention is made of Code Wheels on the W.I.F. and W.O.F. Rollers. On later machines, the Code Wheels have been replaced with notched rollers. W.I.F. Sensor/Roller a Figure 149 shows a W.I.F. Roller without a Code Wheel. W.I.F./W.O.F. Roller This figure shows the end of a new, notched roller. The notches serve the same purpose as the teeth on the Code Wheels. The W.I.F. and W.O.F. Sensors can see the difference between metal and no metal on the end of the rollers, and they create a string of pulses, as the condition changes. W.O.F. Sensor. 1 SENS. The W.O.F. (Web Out of Festoon) Sensor is mounted at the end of the LAST Fixed Finger Idler Roll. A Code Wheel is attached to the roller. The sensor sends out one digital pulse, each time one of the teeth in the Code Wheel passes in front of the sensor. The P.L.C. uses these pulses to calculate the speed of the press or process unit. The sensor has a built-in L.E.D. for troubleshooting. W.O.F. Pulses may also be checked at the P.L.C.

134 CALIBRATION: The gap (space) between the sensor and the Code Wheel should be set to approximately [0.38 mm]. The sensor should be centered over the Code Wheel. W.O.F. Sensor/Code Wheel W.I.F. Sensor. 10 SENS. W.I.F. Sensor/Code Wheel The W.I.F. (Web Into Festoon) Sensor is mounted at the end of the FIRST Fixed Finger Idler Roll. A Code Wheel is attached to the roller. The sensor sends out one digital pulse, each time one of the teeth in the Code Wheel passes in front of the sensor. The P.L.C. uses these pulses to calculate the speed of the web. The sensor has a built-in L.E.D. for troubleshooting. W.I.F. Pulses may also be checked at the P.L.C. CALIBRATION: The gap (space) between the sensor and the Code Wheel should be set to approximately [0.38 mm]. The sensor should be centered over the Code Wheel.

135 Alternate Encoder WIF / WOF Sensors The first roller in the fixed rollers at the top of the accumulator is the WIF (web into festoon) roller. This roller is used to calculate the diameter of the unwinding roll by comparing idler roll pulses (541 per revolution) with roll pulses (4 per revolution). This comparison allows us to quickly calculate the actual diameter of the unwinding roll for precise speed control of the unwinding roll. The last roller in the fixed rollers at the top of the accumulator is the WOF roller (web out of festoon). This roller picks up pulses to give a precise reading of process speed. The roll surface drive follows the process speed during normal run conditions. W.I.F. & W.O.F. Sensors This splicer uses Ring Magnets for W.I.F. & W.O.F. Sensors. This newer system provides higher resolution for W.I.F. and W.O.F. Signals. W.I.F. Sensor/ Ring MAGNET In addition to the higher resolution, the direction of web movement can be monitored. NOTE: Consult the Wiring Diagrams for your splicer, as needed. CALIBRATION: The gap (space) between the sensor and the Ring Magnet must be set to.03 [.8 mm]. The sensor must be centered over the Code Wheel.

136 Ring Magnet Sensor Calibration

137 Dancer Sensors. Dancer Sensors Dancer sensors are used to verify the location of the dancer and change the drive output state in the program. The dancer sensors have a range of 4 mm and are normally set at The top dancer sensor senses that the splicer has run out of storage and thus must stop the process. The dancer has two lower sensors. When the dancer is above these sensors, the PLC gives the drive a command to run at 15% faster than the process. When the dancer reaches the top sensor a signal to match process speed is given to the drive. When two sensor are actuated the unwind speed is slowed by 15%. When the lower sensor alone reads, the roll is stopped. If the unwind output speed causes the web to be unwound either slightly too slow or too fast, the error is slowly integrated into the control output speed to correct for this.

138 The Wiring Diagrams contain a table and a drawing, which explain the purpose of 2SENS (Sensor A, Upper Dancer Sensor) and 3SENS (Sensor B, Lower Dancer Sensor). There are three sensors (2, 3, 7 SENS) that are used to monitor the position of the Dancer. A Steel Bar Target on the Dancer Side Plate is used to trigger the Sensors. 2 Sensor and 3 Sensor are at the BOTTOM of the Dancer travel. 7 Sensor is at the TOP of the Dancer travel. Dancer Zone Sensors. 2, 3 SENS. Dancer ZONE sensors. 2, 3 SENS. Using the signals from these two sensors, the P.L.C. will speed up, slow down or stop the Running Roll Drive Motor, as needed. The sensors have built-in L.E.D.s for troubleshooting. 2SENS and 3SENS outputs may also be checked at the P.L.C. CALIBRATION: The gap (space) between the sensors (White Arrows) and the target (Black Arrow) should be set to approximately 0.02 [0.38 mm]. The vertical spacing of the sensors and the target is determined by their attachment to the splicer and should not be changed.

139 Dancer empty Sensor. 7 SENS. Dancer empty sensor. 7 SENS. 7SENS monitors the Top-Most position of the Dancer travel. If the Dancer Target reaches 7SENS, the Dancer is about to run out of storage. A signal will be sent out, that will stop the press or process unit. Under normal conditions, the Dancer should be DOWN, at the area of 2SENS and 3SENS, except during the Splice Cycle. Actuation of 7SENS indicates an abnormal condition. The sensor has a built-in L.E.D. for troubleshooting. 7SENS may also be checked at the P.L.C. CALIBRATION: The gap (space) between the sensor and the target should be set to approximately [0.38 mm]. The vertical spacing of the sensor and the target is determined by their attachment to the splicer and should not be changed.

140 Auto-Splice/Imminent Sensors Roll diameter Auto-Splice sensor System If your splicer is equipped with the Roll Diameter Auto-Splice System, there will usually be two sensors for each roll position, mounted in brackets, on the splicer side frame. The arrow points to the sensors and the oval outlines the Threaded Rod and Collar. 1 2 Roll diameter Auto-Splice sensors 1. Auto-Splice. 2. Splice Imminent. In the standard, dual sensor arrangement, the sensors will be arranged as shown in Figure 156. If your splicer is equipped with the Roll Core Detector Auto-Splice System, the sensor bracket will only have a single sensor. This single sensor will be used as the Splice Imminent Sensor.

141 5SENS (Upper) or 6SENS (Lower) are used to initiate an Auto-Splice sequence before the web runs off the Running Roll Core. A trigger arm, made from a length of threaded rod, is attached to the pivot shaft for the Roll Drive Module. Rod and 2 sensors As the Roll Diameter decreases, the Roll Drive Module pivots, to follow the outside diameter of the Running Roll. As the Roll Drive Module pivots, the locking collar and support rod move also. When the rod swings down to the area in front of the sensor, a signal is sent to the P.L.C. The position of the arm and thus autosplice diameter is adjusted by loosening the clamp collar and rotating the pivot shaft to actuate at the correct diameter. 1). The rod goes through the collar and bottoms out against the pivot shaft. The threaded rod secured to the collar and pivot shaft with hexagon nuts. There are two additional nuts on the threaded rod. Locking Collar The rod/split collar assembly is secured to the Pivot Shaft by tightening a socket head cap screw which squeezes the split collar onto the pivot shaft. The Upper and Lower sensors are enabled separately. When the Upper Roll is running, the 5SENS (Upper) is enabled through Line 40. Line 41 will only enable 6SENS (Lower) when the Lower Roll is running. The sensors have built-in L.E.D.s for troubleshooting. Both sensors may also be checked at the P.L.C., one at a time. Select the Upper Roll as the Running Roll to check 5SENS. Select the Lower Roll as the Running Roll to check 6SENS.

142 CALIBRATION: The gap (space) between the sensor and the end of the threaded rod should be set to approximately [0.38 mm]. The Sensor is adjustable (in and out) in its bracket, and the bracket allows for some up and down adjustment. SETTING THE AUTO-SPLICE DIAMETER. Create a roll of the desired Auto-Splice Diameter, by any convenient method. Such As: stripping a previously used roll down to the correct diameter. OR Wrap an empty core with some type of material. Install the sample roll in the splicer, and lower the Roll Drive Module onto the roll. Adjust the trigger arm, as described on the preceding page, to turn on the L.E.D. in the sensor body. This setting will be the Auto-Splice Initiation Point. During operation, the Roll Drive Module will pivot down, toward the Roll shaft, as the roll gets smaller. When the correct diameter is reached, the signal from the Auto-Splice Sensor will start the Splice Cycle. THE AUTO-SPLICE DIAMETER MAY BE RESET AT ANY TIME. REMEMBER TO CHECK THE SETTING IF THE ROLL CORE DIAMETER IS CHANGED. Splice Imminent Alarm A FLAG is mounted on the rod/split collar assembly. The Splice Imminent Alarm Sensor is mounted further out of the bracket than the Auto-Splice Diameter Sensor. The Splice Imminent Alarm Sensor should be set to trigger, at a roll diameter that is larger than the Auto-Splice Diameter. Actuation of this sensor will provide a 3-second signal, out of the Butler Controls, to whatever alarm device is attached Rod, flag & 2 sensors 1. Threaded Rod. 2. Splice imminent flag. 3. auto-splice sensor. 4. splice imminent sensor. The figure shows the FLAG on the rod that is used to trigger the Splice Imminent and autosplice Sensors. The angle of the splice imminent flag 2 Rotate the Flag, to actuate the Splice Imminent Sensor, before the Auto-Splice Diameter is triggered. SPECIAL OPTIONS:

143 On request, Butler Automatic Inc. can supply some SPECIAL, OPTIONAL features as original equipment or as retrofit packages. Stack Lights Splicer equipped with a three (3) color stack light. Lights are controlled by splicer PLC and powered from 24VDC power supply. The stack light will be located with the bottom light at a minimum height of six feet. The color code for stack lights will conform to the following: Color Light Function Red On Solid E-Stop, Fault/Alarm, Not Ready to Run Flashing Red Low Materials Splice Imminent and Splice Not Prepared Amber On Solid Splice Prepared Flashing Splice Imminent Green On Solid Ready To Run Ethernet/IP interface Splicer enclosure will have an external GFCI convenience receptacle and PLC Programming port (Ethernet/IP) for Programming of the PLC without requiring that the door be opened. This GFCI will be protected by a circuit breaker. Communication interface module Allen Bradley 1761-NET-ENI will be installed in the electrical enclosure to allow Ethernet/IP communication to the Micrologix 1500 PLC. Adjustable Force Vacuum Vacuum for holding the web in the SP1 Splicer may be supplied by different sources. Standard Vacuum on an SP1 Splicer is created by applying compressed air to a Vacuum Venturi Valve. The splicer may also be connected to a central source of Vacuum, in the plant. Vacuum Pumps may be used to create Vacuum, at the splicer. Among the available SPECIAL OPTIONS, is an Adjustable Force Vacuum Pump. If high vacuum force is applied to light webs, the web could become distorted on the Splice Preparation Bar, causing sealing problems. The ability to adjust the force of the vacuum that is applied to the new web, during Splice Preparation, may be an advantage, on very light or very flexible webs.

144 VACUUM PUMP ON SP1 SPLICER The SPECIAL OPTION Adjustable Vacuum Pump is located on the Operator Side of the SP1 Splicer. PUMP CONTROL BOX The box below the SP1 Control Cabinet contains the motor controls for the Rotary-Vane Vacuum Pump.

145 VACUUM PUMP The Rotary-Vane Vacuum Pump is connected to the Vacuum Select Solenoid Valve, through plastic tubing. The Vacuum Select Solenoid Valve is used to deliver vacuum to the section of the splicing Head opposite the running roll. VACUUM ADJUSTMENT KNOB If you cannot hold the web, in the Splicing Head, turn the Adjustment Knob CLOCKWISE, to increase the Vacuum Force. If the web in the Splicing Head is badly distorted when it is on the Splice Preparation Bar, turn the Adjustment Knob COUNTER-CLOCKWISE, to decrease the Vacuum Force. The MAXIMUM Vacuum Force that is available from the Rotary-Vane Vacuum Pump is 0.86 bar/25 Inches Water Column. DO NOT LUBRICATE THE VACUUM PUMP! There is a decal on the motor, which contains service instructions. Follow the instructions to clean the filter, periodically. Low Air Pressure Switch This switch is a passive system which signals the splicer should the input air pressure ever drop below 60 PSI. If the air pressure drops below 60 PSI, the blue low air pressure indicator light will flash in the stack light.

146 SYSTEM FAULTS ADDITIONAL L.E.D. INFORMATION. In addition to the normal ON/OFF status of the L.E.D.s on the Operators Panel, some of the L.E.D.s will FLASH, to alert the operator to some unusual conditions. SYSTEM FAULT INDICATOR System Fault Indicator Lamp The System Fault Indicator (RED L.E.D.) is located above and to the left of the Butler Logo. IF THE FAULT INDICATOR IS OFF, THE MACHINE STATUS IS NORMAL. Under normal conditions, the System Fault Indicator will be OFF.